PRESSESERVICE

Whether intuitive human-machine interaction systems or tailored electronics solutions: From its German headquarters and plants in Hungary, Italy, Poland, China, and the USA, RAFI supplies a diverse range of industrial sectors. Throughout its corporate history, the company has continuously set new benchmarks. RAFI was founded on November 15, 1900, in the same year as the Nobel Foundation. Originally named “Institut für Elektrotechnik, Optik & Mechanik”, the company immediately launched its innovation trajectory.

“In its 125 years of company history, RAFI has grown into an international high-tech enterprise. We have our founders Ernst Bucher and Raimund Finsterhölzl to thank for this, but also all the individuals from various generations since the beginning who have contributed in Berg and at our other locations,” says Dr. Lothar Seybold, CEO of the RAFI Group. “Our joint work has led to ongoing innovations that not only propelled our company forward but also made a significant impact on the industry as a whole.”
Pioneering development of control systems
RAFI is responsible for major innovations including the development and manufacture of the first ever pushbuttons and switches for machine controls in the 1950s, series switches and control systems for industrial applications and household appliances in the 1960s, and the RAFI keyboard in 1970. This keyboard ushered in the PC age a full six years before the advent of the Apple I computer. In 1977 RAFI launched the RS76 keyboard program that made it the market leader for terminal and office applications, manufactured e.g. under license for Siemens. During the following decade up to 1990, RAFI achieved further pioneering milestones. These included the development and production of flat data entry systems and tactile switches which are still in use in industry today under the name RACON. They ensure individual control, input and operation of machine applications.

Innovations driven by zeitgeist and megatrends
Early in the new millennium, in 2004, RAFI developed a touch control system for WMF coffee machines. In 2012, RAFI launched its own touch sensor production for all types of capacitive control systems in order to meet the need for adequate standards in industry in the smartphone age. In the middle of the 2010s, RAFI broke new records in another segment which plays a key role globally: the production of routers and WLAN devices for internet communication. This area remains an established part of the RAFI product portfolio today.

“The markets we move in are fast-paced and fiercely competitive. Technological advancement requires continuous innovation and rethinking. That demands intensive industry knowledge and tailor-made solutions plus integrated development, design and manufacturing capabilities,” explains Lothar Seybold. He adds: “We draw on many years of experience and cross-industry expertise, for example in medical technology, vehicle, machine, and system engineering, robotics and automation, as well as building and control technology. All this enables us to think and act in multiple dimensions.”

Focus on corporate culture and sustainability
Seybold points out the company’s longstanding relationships with industry leaders and also emphasizes the in-house development and manufacturing of both components and software elements. Flat hierarchies and direct communication channels ensure fast and efficient processes. Lothar Arnold, CFO of the RAFI Group, explains that sustainability is also firmly anchored in the organization and management system and forms an integral part of the international corporate culture. “In 2023, the rating agency EcoVadis awarded us its silver medal for our sustainability efforts, and in 2024 we topped that with a gold medal. This award motivates us to continuously improve and constantly review and optimize our organization, processes, and products.”

In 2024 RAFI signed up to the UN Global Compact. Based on ten universal principles and the 17 Sustainable Development Goals (SDGs), the initiative pursues “the vision of a more inclusive and sustainable economy for the benefit of all people, communities, and markets, both now and in the future.”

Development of platform technologies and expansion of locations
RAFI is dedicated to continuing its role as a source of ideas and inspiration for its customers into the future. The portfolio will develop, adjusting not only to the latest market requirements, but also creating new platform technologies that provide added value. “We develop basic technologies, hardware assemblies, and both IoT and embedded software. Our products are tailored to each customer project in their particular industry and can be applied worldwide. The customer benefits from risk minimization, development cost savings, and shorter development periods,” says Lothar Seybold, summing up the big picture. This pooling of expertise, competence, and knowledge is ideal for tapping into both traditional and new markets.

Naturally, the resulting growth demands an expansion of the company’s resources. One example is the new RAFI plant in Bad Waldsee, which will start operations in early 2025. The investment also demonstrates the company’s commitment to the region. “Covering a floorspace of 10,000 m², the facility will include new production shops for synthetic materials and automatic machines, metal processing, tool and die making, tool and die development, and the new training and apprentice center, RAFI Academy”, says Lothar Arnold. A major priority for RAFI with this new building was an energy efficient infrastructure in compliance with the EFFH 40 standard. The primary energy source will be a geothermal probe system with 34 probes installed at a depth of 131 m. Additional energy will be provided by a PV system with a performance of 760 kWp.

RAFI also remains committed to its international growth strategy and plans to further expand capacities above all in Asia and the USA. In 2023, RAFI acquired Xymox Technologies, which draws on more than 40 years of experience in the development and production of capacitive input sensors and membrane switches. Further initiatives may follow.

Training, voluntary work and roots in the community
Apart from expanding its product portfolio and developing company locations, RAFI also maintains a focus on supporting young career-starters. This involves offering opportunities for dual study programs, internships, and training. Last fall, 11 trainees, two retrainees, and 13 dual-study students embarked on trade, commercial, or technical qualification programs. Currently, RAFI employs a total of 72 trainees and students.

There is a long tradition of company sports activities at RAFI. Last year, the company sports groups celebrated their 50th anniversary. The variety of sporting activities is huge: from fitness training to gymnastics, bowling, bouldering, cycling, swimming, tennis, and archery.

“RAFI Heroes – Spotlight on Voluntary Work” offers employees the chance to nominate their favorite charity projects for company support. In the past two years, RAFI chose a selection of especially impressive projects from a large number of inspiring entries. “As a part of society, we feel a duty to contribute to improving our community. Voluntary workers often dedicate much of their spare time to taking on social responsibility. That’s why it is and will always be important to us to also support carefully chosen local organizations and initiatives,” says Lothar Arnold. Additionally, RAFI supports regional soccer and ice hockey clubs.

Menzel Elektromotoren has delivered its largest low-voltage motor to date – it weighs a total of 19800 kg. The motor drives a cooling water pump in a combined heat and power plant in Venice. Previously, several motors had failed in a short time in this application, probably due to unsuitable designs. Menzel customized its new motor specifically for the pump application and proved in load tests that it provides the required output power at the various load points. The MEBKSL-type three-phase squirrel-cage motor is designed as a vertical motor in construction type IM 3011 (IM V1) with a 710 mm shaft height. It boasts 650 kW rated power, 690 V rated voltage and 16731 Nm rated torque. The family-run German motor manufacturer had a suitable 12-pole converter motor with 31-Hz star winding in stock and therefore could complete the order very quickly – only seven weeks passed between first inquiry and the motor’s arrival at the installation site. The motor’s electrical data were perfectly suited to the application, needing only minor changes to the converter parameterization on site. The mechanical adjustments were all the greater. The motor’s cooling type IC 86W (water-cooled) had to be converted to IC 666 (air-cooled). Menzel built an adapter for an in-stock air cooler and modified the air flow in the motor casing. Menzel also manufactured an individual adapter flange for mounting on the pump and adapted the shaft dimensions. The pump motor features IP55 protection. In its new energy-efficient paint shop, Menzel also finished it with a special coat of paint against aggressive climatic conditions.
More about Menzel’s application-specific squirrel-cage motors: https://www.menzel-motors.com/squirrel-cage-motor/

On behalf of Daimler Truck AG, RAFI has developed a compact control console with touchscreen and optional joystick operation for the implement carriers of the new UNIMOG model series. The variably adjustable multi-touch system for controlling attachments and the working hydraulics is now in series production. The core of the control system is the ergonomic center console with integrated switching elements, which can be optimally positioned for various operating scenarios, including a driver seat side change in conjunction with a switchable steering system. Easily customizable function keys allow for convenient access to commonly used features and the ability to flexibly adjust control options to various attachable and mountable implements. In addition to up to four linear joysticks with capacitive finger detection for controlling the working hydraulics, the console also features additional control wheels and memory key switches for operating attachable implements. Inside, a high-performance embedded control unit from RAFI’s ECU range ensures rapid signal and data communication. The 10.5″ touchscreen mounted at the head end ensures user-friendly menu navigation for accessing function and status indications, as well as for configuring and customizing profiles, sequences, and operating elements using touch controls. The display can be rotated and tilted for optimal viewing and can also be folded down for storage when not in use. As an additional operating option, RAFI has designed an ergonomic joystick especially for the right hand. The new control lever, built on the JOYSCAPE joystick platform, features four splitters and wear-free 3D Hall sensors. It includes three customizable key switches, two rotary encoders, a sensor panel, and capacitive hand detection to prevent operating errors. The plug-in control lever can be positioned on the right-hand armrest of the driver or front passenger, as well as in the parking position on the storage compartment.

RAFI has developed and produced a state-of-the-art display system with capacitive touch functionality for the UNITED GRINDING Group, one of the world’s leading manufacturers of grinding machines, eroding machines, laser machines, measuring machines, and machine tools for additive manufacturing. The 23.8″ full HD multi-touch display serves as a standardized solution for the entire machine range across all brands within the Group, offering an intuitive and user-friendly touch interface alongside enhanced functionality. Based on the RAFI GLASSCAPE technology platform, the input and display system provides operating comfort akin to that of smartphones. It also received a “Special Mention” at the UX Design Awards for its exceptional user and customer experience. The extensive range of features is complemented by editable role profiles, individual user customization, and compatibility with digital networking at the IIoT level. The HDBaseT standard gateway developed by RAFI allows for a sleek device design, eliminating the need for extra control units and cooling systems within the display panel. This is achieved by offloading signal control and data transmission to the machine’s CPU through HDBaseT technology. The HDBaseT interface ensures lossless real-time transmission of video and audio signals, user input, and USB communication, as well as internet and network protocols. Data rates of up to 8 Gbit/s also support video transmissions with 4K resolution. The large display diagonal provides ample room for intuitive user interfaces featuring customizable, self-explanatory icons. RAFI has incorporated ultra-flat actuators from its RAFIX 30 FS+ series into the console of the swiveling and tilting panel located beneath the display. RAFIX actuators paired with MICON 5S micro-switches provide precise tactile feedback, exceptional switching reliability, and minimized space requirements. A USB feed-through from the RAFIX 22 FS+ series is used for data transmission. The LUMOTAST 16, known for its reliability in mechanical and plant engineering, is used as an emergency stop key switch. One operating highlight is the inductive rotary switch with override function, which enables all machine movements to be limited in a coordinated and infinitely variable manner via rotary input. The system now features automatic radar user recognition along with an integrated front camera, enabling direct video calls with the Customer Care team of the UNITED GRINDING Group.

By provisioning in good time, plant operators can avoid costly downtimes. This is all the more important for non-standard configurations. An Argentinian steel mill operator commissioned Menzel Elektromotoren to build a special motor based on an existing motor with the type of construction IM 7311. For future-proofing and since this is a considerable investment, the old, still operational motor is to be stored as backup. Therefore, the new machine must replicate it in every detail, although Menzel implemented a performance increase at the customer’s request. The German, family-run company counts special motors among its core business and also designed the starter in such a way that it caters for the new motor and the original one equally. The new slip ring motor provides a nominal torque of 43245 Nm at 6600 V rated voltage and 1345 kW rated power. The format is unusual: at a total weight of 21.9 tons, the rotor alone weighs full 10.4 tons. Various accessories were installed, including HALL effect current transformers to measure the rotor current, customer-specified accelerometers on the bearings, and a level sensor for the electrolyte in the starter. The motor features IP23 protection and IC 01 cooling (open-circuit ventilation). It has to withstand ambient temperatures up to 45 °C in the rolling mill. Before shipping, the motor underwent a complete type test with additional tests according to customer specifications, including partial discharge and dissipation factor measurement (tan d). Menzel will also handle the mill drive commissioning, which the operator will schedule to suit production planning.
More information about customized motors: https://www.menzel-motors.com/modification/

RAFI has developed the FLEXLAB labeling system for the flexible labeling of its RAFIX and RAMO pushbuttons or illuminated attachment panels. In addition to transparent, pre-punched labeling sheets in printed or unprinted versions that can be designed by the customer, RAFI also offers symbol printing on the pushbutton panels in black font color. RAFI has expanded the range of labeling options for FLEXLAB pushbuttons and illuminated attachments for printing standard symbols on the cover. In addition to transparent panels, translucent green or red-colored panels are also available for the distinctive marking of on and off or start and stop functions. The manufacturer marks the reset button on transparent and blue-colored bezels as standard. In addition, transparent bezels can be printed with numerous standard symbols. The round, 22.15mm apertures are designed for working temperatures from -25°C to +70°C and are attached to FLEXLAB pushbuttons and illuminated attachments by latching.

Menzel Elektromotoren has built a dust-explosion-protected motor in ignition protection type Ex tc (protection by housing) and provided it with the ATEX label II 3D Ex tc IIIB T125 °C Dc for use in zone 22 hazardous areas. The German motor manufacturer application-tailored the 1120-kW squirrel cage motor for a leading Italian operator’s flour mill. Menzel used a machine from its extensive stock, upgraded it for converter operation, adapted the dimensions to the existing motor to enable a smooth replacement, and manufactured an oversized terminal box according to customer specifications. The mill motor with a nominal voltage of 690 V provides a nominal torque of 11575 Nm. It is suitable for operation in both directions of rotation and features protection class IP55 with IC 611 cooling (CACA air-to-air heat exchanger). Through its Italian subsidiary, Menzel has been the mill operator’s trusted motor supplier for many years. Thanks to its large motor warehouse, application-specific configurations and ATEX certification capability, Menzel can meet virtually any demand from a single source.
More about low, medium and high-voltage motors in ignition protection types Ex ec and Ex tc for zone 2 and zone 22 hazardous areas with a risk of gas or dust explosions: https://www.menzel-motors.com/ex-na/

LOSYCO designs and builds customized heavy-duty transport solutions based on its floor-level LOXrail system. Now, the intra-logistics specialist has expanded the system to include new transport trolleys with a telescopic loading area. Heavy-duty LOXrail trolleys manufactured for a modular timber construction company are designed for load capacities of up to four tons and can be extended from 2.5 m to 4 m wide in six increments. This allows users to pick up payloads in different sizes without changing the track width and to move them manually. The trolleys, which also serve as working platforms, feature floor brakes attached to the side of the platforms that are engaged via a pedal to ensure a secure hold. The trolleys travel on rails with a 25-mm shaft diameter. LOSYCO has equipped them with two patented AllRounder wheelsets each to facilitate lane changes between different production lines. Two rollers mounted at an angle can be rotated in opposite directions in order to realize effortless 90° turns at junction points. Locking bolts attached to the carriages ensure secure positioning on the turning point. This enables rail layouts with linking and crisscrossing lines without the need for additional, high-maintenance shunting equipment. Up to seven of the new heavy-duty trolleys can be connected by coupling rods to form a transport train of around 14 m in length, which employees can move by hand. At the end of the route, the 300-kg trolleys are returned by forklift.

The new IP66-rated protective camera enclosure Sparrow from autoVimation provides cost-effective protection with the accustomed quality for typical machine vision cameras with cross sections of 29 mm x 29 mm or 30 mm x 30 mm and maximum lens diameters of 40 mm. The enclosure body has an inner length of 160 mm. With a flat front lid and the 40-mm enclosure extension included in delivery, users can easily access the lens settings. Without the extension, the flat lid is perfect for cameras with S-mount lenses. The cable gland allows one or more cables and plugs with diameters up to 21 mm to be fed through. The sealing insert is closed; users drill the holes for the cables themselves. In keeping with the straightforward enclosure concept, the manufacturer also offers a stripped-down swivel/tilt mount, which is less robust than the conventional milled versions, but is fully sufficient for applications with lighter mechanical load.

EGE expands its range of IO-Link sensors, launching an entire new series of flow sensors for smart networking in compact plants and systems. The new SDNB 552 series is based on a tried and tested special model. Four series sensors measure the flow velocity and temperature of water-based liquids in ranges between 0.5…10 l/min and 5…100 l/min with linearized measured value output. The IO-Link interface allows for convenient remote sensor parameterization and data read out for maintenance. The analog output and switching output are available in SIO mode. Parameterization with IO-Link via the M12 connection is carried out either via a PLC or an IO-Link master – EGE offers the IOL Master Set V1.1 for this purpose. The sensors featuring G1/2 or G3/4 connection threads are designed for inline mounting in hoses and pipes. Based on the calorimetric measuring principle, the sensors introduce no moving parts or deflectors into the stream. The wetted parts are made of 1.4571 stainless steel. The sensors are IP65-rated, pressure-resistant up to 10 bar and designed for media temperatures from 0 °C to 60 °C. Due to their rugged design, EGE flow sensors withstand moisture and vibrations.
More about the series: https://www.ege-elektronik.com/products/sdnb-552-1