HSD Mechatronics
Monolithic milling head for metal machining
HSD Mechatronics expands its premium metal machining range, adding the newly developed, exceptionally powerful and robust milling head HST810DS XL for demanding cutting processes. The new premium model delivers outstanding positioning speed, precision and rigidity.full text
The HST810 platform continues to evolve. HSD designed the HST810DS XL milling head for applications that require significantly higher torque and greater structural rigidity, such as machining aluminium alloys and steel components with high material removal rates.
To meet these specific requirements, the engineering team substantially upgraded the axis torque, nearly doubling it compared to the standard version. This ensures greater stability and consistent performance even under demanding cutting conditions.
HSD also redesigned the head structure using cast iron. This material choice improves damping characteristics and overall rigidity, making the unit particularly well suited to sectors like aerospace where vibration control and machining precision are critical.
These deliberate enhancements extend the platform’s application range beyond composite materials. The HST810DS XL is a robust solution for challenging metal machining processes, which retains the established integration philosophy and flexibility that OEMs require.
The HST810DS XL with its monolithic cast-iron housing weighs approximately 750 kg. The two-axis milling head series features an HSD direct drive motor. It delivers a continuous torque of 1000 Nm and a peak torque of 1800 Nm on the A-axis. The C-axis values are 970 Nm and 1800 Nm respectively. The measurement system accuracy for both axes is ±2 µm, with a positioning accuracy of ±8 µm and a repeatability of ±5 µm. The matching ES511 electric spindle with an HSK A100 tool interface delivers 63 kW (in duty type S1) and 200 Nm (S1) at a maximum speed of 13,000 rpm, with permanently greased bearings.
CONTA-CLIP
Exhibitor debut at leading tradeshow for transportation technology
Conta-Clip shows new rail-certified cable entries at InnoTrans 2026
Conta-Clip makes its InnoTrans debut, showcasing new rail-certified cable entry systems. KDS-DE-Rail and KDS-DEG-Rail comply with EN 61373 and HL3 and combine fast, tool-free installation with IP66 protection.full text
InnoTrans, the international leading trade fair for transportation technology, celebrates its 30th anniversary in 2026. The Berlin show runs from September 22 to 25 with a focus on safety and effective fire protection in modern rail transport.
Passenger safety rightfully comes first, but speed is equally important for success. Conta-Clip’s cable entry systems for rail applications deliver both. The new KDS-Rail systems ensure compliance and protection for passengers and operators: KDS-DE-Rail and KDS-DEG-Rail are tested to EN 61373 and carry the HL3 approval. They also save much installation time – both in initial setups and when adding or replacing cables.
InnoTrans visitors can see these advantages firsthand at the Conta-Clip booth. The KDS cable management system is part of a comprehensive modular portfolio for routing and feeding cables with and without connectors. Key features include high flexibility, tool-free installation from outside to inside or inside to outside, and an IP66 protection rating. The system enables smart cable routing in control cabinets, machines or enclosures and adapts to changing requirements at any time without removing the frame.
Conta-Clip at InnoTrans 2026: Hall 12, Booth 77
MENZEL
Large Ex ec motor for refinery in two weeks
Menzel Elektromotoren delivered an explosion-proof pump motor rated 1,686 kW for Gas Ex Zone 2 to an English refinery in just two weeks. Thanks to extensive stock and in-house manufacturing, the family-run company prevented a production shutdown that could have lasted months.full text
Menzel Elektromotoren has supplied an English refinery with an urgently needed replacement for a failed main pump motor in a Gas Explosion Zone 2 hazardous area. The motor manufacturer routinely handles emergency orders. Customers who would otherwise face months of production downtime avoid major financial losses as a result. In the present case, just one day separated initial inquiry, quote and order. Two calendar weeks later, Menzel shipped the finished motor.
The Berlin-based manufacturer is certified for producing large three-phase motors to ignition protection type Ex ec (“increased safety”). It maintains a large inventory of motors and accessories and can implement many designs, equipment options and cooling types quickly in-house.
The squirrel-cage motor built for the refinery is rated for an output of 1,686 kW at 3,300 V, delivering a speed of 2,964 rpm and a torque of 5,432 Nm at the rated operating point. Menzel’s explosion protection specialists labeled the motor II 3G Ex ec IIB T3 Gc. The Ex ec protection type ensures that the motor generates no ignitable sparks during normal operation and surface temperatures remain within safe limits.
The MEBKSL-type motor has a shaft height of 500 mm and weighs 6.6 t. It features protection class IP55 and an air-to-air heat exchanger (cooling type IC 611). Because the oil industry application required reverse rotation, the manufacturer reversed the fan blades – the most time-consuming step in the entire project. Beyond that, Menzel adapted the motor in every mechanical and electrical detail so the customer could install and commission it as a direct drop-in replacement, with no modifications required either to the motor or to the existing installation. The proven MEBKSL motor series design ensures reliable, long-lasting and efficient operation.
More about explosion protection and ATEX certification for electric motors in gas and dust hazardous areas:
https://www.menzel-motors.com/ex-na/
LOSYCO
Ten years of rail-based production logistics
LOSYCO marks its first decade
German production logistics specialist LOSYCO celebrates its tenth anniversary. Founded in April 2016 by experienced engineers, the expert for rail-based heavy-duty intra-logistics has grown into a global systems provider of integrated solutions for production and warehouse logistics as well as heavy-load material feeding.full text
German production logistics specialist LOSYCO celebrates its tenth anniversary. Founded in April 2016 by experienced engineers, the expert for rail-based heavy-duty intra-logistics has grown into a global systems provider of integrated solutions for production and warehouse logistics as well as heavy-load material feeding.
Based on its flush-mounted LOXrail system, LOSYCO designs, manufactures and installs custom intra-logistics systems with application-specific transport trolleys for the tooling and agricultural machinery industries, wind turbine production, prefabricated building construction and many other sectors worldwide. The technology enables workers in flow production lines to move multi-ton payloads manually without auxiliary power. Alternatively, battery-powered and inductively fed drive concepts are available.
The most recent addition to the product range, the LOXrail smartCURVE system navigates curves and corners and combines the load capacity of conventional rails with the automation level of modern automated guided vehicle (AGV) technology for heavy-load transport at Industry 4.0 levels. LOSYCO has also developed high-precision systems with various automated feeding options for robot cells, laser cutting machines and other applications. In warehouse logistics, the robust LOXrail systems have proven their value as an economical, low-wear and barrier-free transport solution.
Since company founder Derek P. Clark stepped down from management in 2020, LOSYCO has been led by industrial engineer Manuel Granz. He states, “We are proud of our success story and the many projects we have completed worldwide in 10 years. We have grown continuously since our founding and have steadily opened up new business areas through innovative system extensions. We will continue to offer our customers forward-looking conveyor concepts tailored precisely to their applications.”
HSD Mechatronics
HSD at AMB 2026: Motorised spindles, milling heads, smart connectivity
HSD showcases a cross-section of its solutions for metalworking at the AMB tradeshow, positioning itself as a system supplier for boring heads, motorised spindles and 2-axis milling heads.full text
The metalworking world meets at the AMB tradeshow in Stuttgart, Germany, from 15 to 19 September 2026. HSD’s mechatronics specialists present their latest and most innovative system solutions at one of the industry’s leading trade fairs.
Since 1982, the who’s who of the metalworking industry has been gathering in Stuttgart, Germany, for the AMB tradeshow every other autumn, and HSD always takes part. The Italian manufacturer showcases a cross-section of its solutions, positioning itself as a system supplier for boring heads, motorised spindles and 2-axis milling heads. Tradeshow visitors are invited to explore various technologies that offer concrete advantages for everyday production and meet daily operational demands. Trained technical staff and sales specialists are on hand to advise and support users.
Showcases include both established and new milling heads and electric spindles, including selected models from the ES5, ES10 and ES60 product lines as well as the HST series. Visitors can examine the robust, precise and thermally stable tools up close. HSD now also offers the HST810 milling head in an extra-large version. HSD designed the HST810XL specifically for demanding machining of steel and light alloys. The cast-iron head delivers almost double the torque of the standard version and features greater structural rigidity. This effectively dampens vibrations and improves stability and precision in heavy-duty machining operations. The XL version is geared at the aerospace industry.
Further highlights include the robust and fast HST610 2-axis milling head for gigacasting applications and the compact, precise and versatile ES510 motorised spindle, purpose-built for demanding applications. Also on show are the ES1000 and ES6000 motorised spindles, which HSD developed to address specific customer requirements. Both product lines reflect the state of the art and adapt to the diverse needs of users as well as the ever-increasing pace of the market. New ES10-line high-tech spindles stand out with smart options for challenging milling processes. The horizontal ES6000 is tailored specifically to the automotive sector. Its design and sensor technology deliver even greater performance and reliability.
Anticipating digital and Industry 4.0 trends, the spindle specialist presents a connecting device that links HSD motorised spindles to the myHSD IoT platform via a range of sensors. This in-house development promotes innovative manufacturing and makes workflows more efficient and effective. The device boosts productivity and quality by detecting faults early and minimising downtime. HSD developed the platform specifically for cost reduction and real-time data analysis. It improves overall processes and helps optimise maintenance through timely alerts and targeted problem-solving measures. HSD applies these concepts in its own production facilities.
Ferdinand Dannenmann, Head of HSD DACH (Germany, Austria, Switzerland), and his team are looking forward to productive meetings in Stuttgart: “AMB is one of the most important trade fairs in Central Europe and gives us the opportunity to engage with our customers in person. HSD is available to all machine tool manufacturers as a reliable partner in spindle and milling head technology. In short, by working with us, manufacturers gain a proven system supplier with extensive experience in key mechatronic systems.”
HSD at AMB: Hall 6, Booth 6D82
The flexibly programmable SMART ENCODER from RAFI can be optimally adapted to specific application requirements in terms of detent behavior, torque, and angle. Image source: RAFI
The SMART ENCODER from RAFI offers individually customizable, realistic haptic feedback for a wide variety of applications. Image source: RAFI
RAFI
RAFI SMART ENCODER: Adaptive encoder with programmable haptic feedback
With the Smart Encoder, RAFI is expanding its portfolio to include a software-controlled, haptic rotary encoder that enables a completely new user experience. The encoder redefines the function of traditional rotary encoders by offering customizable, realistic haptic feedback for a wide variety of applications. full text
With the Smart Encoder, RAFI is expanding its portfolio to include a software-controlled, haptic rotary encoder that enables a completely new user experience. The encoder redefines the function of traditional rotary encoders by offering customizable, realistic haptic feedback for a wide variety of applications.
At the heart of the system is fully programmable haptics: click behavior, torque, end stops, and return to a center position can all be flexibly configured via software. This allows the tactile behavior to be precisely tailored to the specific function or user requirement.
Among other features, the Smart Encoder enables a variable number and intensity of detents, dynamic and context-dependent end stops, and active return to the center position, which creates a spring-like operating feel. In addition, dynamic torque control allows for real-time adjustment of resistance, ensuring particularly intuitive and precise user feedback.
Thanks to this flexibility, the Smart Encoder functions as an intelligent haptic interface that actively interacts with the user. The result is intuitive operation, greater operational safety, and a significant reduction in operating errors.
As a standardized platform solution, the Smart Encoder can be used in a wide range of applications, from industry and mechanical engineering to medical technology and agricultural and construction machinery. Developers and manufacturers benefit from a uniform, flexibly adaptable solution for a wide variety of application scenarios.
GMC-I Messtechnik
GOSSEN Introduces New MAVOBASE-LUX Model in the Field of Light Measurement Technology
With the new MAVOBASE line, GOSSEN Photo and Light Measurement Technology is launching a series of measuring instruments that combines precise measurement technology, ease of use, and an attractive price-performance ratio. full text
With the new MAVOBASE line, GOSSEN Photo and Light Measurement Technology is launching a series of measuring instruments that combines precise measurement technology, ease of use, and an attractive price-performance ratio. The series is aimed at users in industry, trade, and quality assurance who require reliable measurement results without having to resort to costly high-end solutions.
The MAVOBASE LUX is an illuminance meter compliant with DIN 5032-7 Class C, designed for standard-compliant measurements in workplaces, production environments, and during maintenance and inspection tasks. Equipped with useful measurement functions such as relative measurement to correct the measured value in the presence of stray light or daylight and MIN/MAX/AVG functionality, it offers the necessary flexibility for a wide range of applications.
The device features a robust design, compact dimensions, and intuitive operation. The new model focuses on practical handling and reproducible measurement results in daily use. In addition, DAkkS and factory calibrations are offered by our accredited lighting laboratory. With the MAVOBASE series, GOSSEN is expanding its portfolio to include a cost-effective solution for professional light measurements, specifically bridging the gap between entry-level and high-end measuring instruments.
HSD Mechatronics
Dynamic milling heads for metalworking
HSD Mechatronics announces its newly developed HST-Line of premium range 1- and 2-axis milling heads for demanding metal machining. Engineered to deliver maximum positioning speed, precision and robustness, these milling heads are the manufacturer’s most powerful product series and are used primarily in metalworking.full text
HSD Mechatronics announces its newly developed HST-Line of premium range 1- and 2-axis milling heads for demanding metal machining. Engineered to deliver maximum positioning speed, precision and robustness, these milling heads are the manufacturer’s most powerful product series and are used primarily in metalworking.
HST-Line milling heads are available in a variety of scalable sizes, including the models HST610MS, HST610DS, HST810MS, HST810DS and HST910DS. All milling heads feature high dynamics, precision and direct-drive axes. They are paired with HSD’s own direct-drive motors (IPM synchronous motors) for outstanding reliability and performance. The heads are suited to demanding machining operations including milling, turning, drilling and thread cutting, particularly on cast iron and steel. Typical target machines include gantry milling machines and other CNC systems.
As a key feature, the HST heads can integrate electric spindles running at up to 24,000 rpm with permanent grease lubrication. This capability unique to HSD enables high performance in the most demanding applications. The direct-drive configuration delivers excellent dynamics without additional components such as cabinet chokes. This translates into clear economic advantages. Fewer components in the control cabinet, a smaller footprint and reduced cooling requirements all contribute to lower overall costs. HST-Line milling heads offer an excellent price–performance ratio and are commonly more cost-effective than equivalent in-house developments.
In modern gigacasting plants for the automotive industry, HST-Line heads symmetrically machine complete car body parts from die castings in a single operation. They boost efficiency by reducing cycle times while maintaining high quality and accuracy. Aerospace manufacturers, too, benefit from the combination of speed, precision and durability. Thus, the series reinforces HSD Mechatronics’ position as a leading provider of mechatronic solutions for high-performance industrial manufacturing.
INELTA
Digital LVDT Displacement Sensor:
Fewer Variants, Greater Flexibility
INELTA Sensorsysteme has played a key role in advancing the digitization of proven LVDT technology and has successfully established it, particularly in hydraulic applications. Applying this concept to additional designs and areas of use opens up new possibilities for industrial displacement measurement. In the future, users will benefit from greater flexibility, reduced procurement effort, and simplified inventory management.full text
INELTA Sensorsysteme has played a key role in advancing the digitization of proven LVDT technology and has successfully established it, particularly in hydraulic applications. Applying this concept to additional designs and areas of use opens up new possibilities for industrial displacement measurement. In the future, users will benefit from greater flexibility, reduced procurement effort, and simplified inventory management.
Digital Linear Variable Differential Transformers (LVDTs) can be configured via software. To achieve this, INELTA Sensorsysteme stores multiple customer-specific measuring ranges within a single sensor type. Users can parameterize the sensor on-site to the measuring range required for a given application. In addition, the characteristic curve can be shifted to compensate for installation tolerances. This eliminates the need for system recalibration when replacing a sensor. Signal inversion is also possible.
Thanks to its scalable preconfiguration, a single displacement sensor replaces multiple variants and combines different specifications in a single housing. This enables INELTA Sensorsysteme to make the advantages of digital LVDT displacement sensors available for additional application areas and industries. Significant cost-saving potential exists, particularly in automation technology, but also in other industrial sectors where different measurement ranges and a minimal number of variants are required.
MENZEL
Coloring book for future motor engineers
Menzel Elektromotoren has published the world’s first coloring book about industrial motor manufacturing. Illustrations based on photographs from the shopfloor invite children to discover how large electric motors are made and develop an early interest in engineering and technology.full text
Menzel Elektromotoren makes its case for a career in electric motor engineering even to the youngest generation. The Berlin-based company takes an original approach and is the first industrial manufacturer to publish a coloring book about its work. Children of preschool and elementary-school age can explore how large industrial motors are built.
“The coloring book is meant to bring children joy and spark curiosity about technology along the way,” says Anja Leipold, head of marketing at Menzel. “We already partner with schools in our region to raise awareness of motor technology and attract young people to apprenticeship programs. Our industry is vital to every branch of manufacturing and the economy. It’s never too early to get the next generation interested in what we do. Who better than a motor manufacturer to show what goes into building, testing, servicing and repairing electric motors?”
The coloring book portrays a varied line of work at the intersection of skilled trades, electrical and mechanical engineering and industrial production. The illustrations are based on photographs from the shopfloor and depict the manufacture of large electric motors in precise detail.
Menzel takes talent development seriously. The family-run business, now in the third generation and approaching its centennial in 2027, trains young people as electrical machine and drive systems technicians every year. Employees tend to stay for the long term, and family members frequently follow – possibly the strongest endorsement any employer can earn.
For more images and background, visit https://www.menzel-motors.com/article/first-coloring-book-on-electric-motor-manufacturing/.
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