Manufacturing Technology

A new technology could improve the efficiency of large-scale manufacturing projects by enabling firms to perform electron beam welding without a vacuum chamber. EBFLOW, which features a local coarse vacuum that can be transported to and operated on site, has been developed by Cambridge Vacuum Engineering and was launched on 1st January 2018. The technology is designed to simplify the process of thick section welding in the manufacture of a wide range of large structures including ships, pressure vessels, wind farms and towers, nuclear plants, and many of the structures involved in oil and gas exploration and civil engineering projects. To date it’s only been possible to perform electron beam welding – a key technology in the fabrication of large, heavy wall structures – at sites equipped with a vacuum chamber large enough to house the structures under manufacture. But EBFLOW’s coarse vacuum can be mounted on tracks and operated locally. The technology can be used in any plant where large components are welded. In tests, EBFLOW has been shown to be 20 to 30 times faster than conventional arc welding, offering transformational gains in productivity. At the same time, it uses less power than conventional arc processes, lowering a plant’s carbon footprint. Among the myriad of other benefits are the ability to perform low-heat input welds that result in reduced distortion – ensuring quality – and the option to perform NDT testing immediately after welding, fast-tracking the manufacturing process and driving down costs. Speaking ahead of the launch Bob Nicolson, Managing Director at Cambridge Vacuum Engineering said: “This technology will transform the productivity of fabrication processes throughout the world of heavy engineering. In many cases the speed of welding can be 30 times faster than current methods. “The technology has been fully developed and pioneered in Britain and we are now ready to […]

 FARO’s next generation Design ScanArm 2.0 is specifically designed to address the most demanding challenges and requirements faced by product design and product engineering professionals. It offers an exceptional combination of flexibility, reliability, value and performance through best in class accuracy, resolution and ergonomics. Performance Design ScanArm 2.0 delivers up to 25% improved system accuracy compared to the previous generation. Design and product engineering professionals can now have increased confidence that the real-world design output conforms even more tightly to the look, feel and complex geometry of the source object. Furthermore, productivity is enhanced with the addition of FAROBlu Laser Line Probe HD that incorporates advanced blue laser technology and rapid scanning of up to 600,000 points per second.  Flexibility and Portability Design ScanArm 2.0 is now available in three highly maneuverable arm lengths – 2.5m, 3.5m and 4m – to ensure that end users can select the option that optimally fits with the specific design objectives for their projects. It includes the option of dual, hot swappable batteries that enable continuous operation wherever needed without the requirement for external power. Users can now bring the scan to the project rather than needing to bring the project to the scan. Usability Enhanced ergonomics and a 25% overall weight reduction enables less operator fatigue. This leap forward in comfort, combined with improved maneuverability, significantly increases productivity by facilitating continuous use over extended periods during the workday. Design ScanArm 2.0 enables a new level of efficiency with integration of a kinematic intelligent probe system for projects that require contact measurement. This system includes a tool less quick release for fast connect/disconnect and allows operators to quickly transition from contact to non-contact projects without needing to spend any significant additional time and effort to switch out or recalibrate probes.      

Jim Plouffe, The Lead South Australia South Australia’s lithium-ion battery grabbed the headlines in 2017, first when Elon Musk announced he’d build the world’s largest battery in 100 days or it would be free, then again when he accomplished it, and yet again when the battery reacted to power surges in record time in December. But the big battery is really just part of the ongoing renewable energy story of South Australia. The year kicked off with the South Australian government launching the $550 million South Australian Energy Plan, which includes a $150 million Renewable Technology Fund that will provide $75 million in grants and $75 million in loans to help private companies and entrepreneurs develop eligible projects. Musk’s now famous battery was one of the first projects to be funded, receiving $20 million to story the energy from the Hornsdale wind farm in South Australia’s Mid North, which is owned by French renewable company Neoen. Tesla CEO Elon Musk and South Australian Premier Jay Weatherill announce the world’s largest battery at Hornsdale Wind Farm in the state’s Mid-North. Picture: Andre Castellucci/InDaily Global energy companies have taken notice of South Australia’s leadership in renewables and began investing in the state in earnest in 2017. In August Solar Reserve announced it would build a 150MW solar thermal in Port Augusta, incorporating eight hours of storage or 1100MWh, allowing it to operate like a conventional coal or gas power station. Electricity retailer Snowy Hydro and Singapore-based renewable energy developer Equis will also build a 100 MW solar farm near Tailem Bend, 100 km southeast of Adelaide. Reach Solar currently have the 220 MW Bungala solar farm about 12km from Port Augusta under construction, with Origin Energy entering a power purchase agreement for the output of the project. Lyon Group also plans to […]

Cloud-based system from Rockwell Automation provides intuitive access to machine information The Industrial Internet of Things (IIoT) has increased the availability of information throughout the enterprise by orchestrating data from multiple sources and applying machine-learning applications. But the power of new IIoT tools to improve machine performance is limited when those with access to information are not experts on the machine, leaving powerful machine information untapped. To better connect industrial producers with expertise outside their production environment, Rockwell Automation offers the FactoryTalk Analytics for Machines cloud for OEMs. Cloud-enabled analytics provide machine data organised in intuitive dashboards that pull from machines deployed across the globe. “By bringing the expertise of OEMs into a producer’s ecosystem, smart machines perform better, and critical process anomalies can be quickly resolved,” said Todd Smith, product manager at Rockwell Automation. “Cloud-based machine analytics give OEMs real-time and historical insights into how their equipment is operating from anywhere, so they can collaborate with customers to help reduce downtime.” An IIoT-enabled packaging machine from Cama Group showcases the value of increased collaboration to both OEMs and end users. The machine offers independent cart technology for fast changeovers, while the FactoryTalk Analytics for Machines cloud relays critical KPI data to the cloud. Real-time performance insights are displayed to Cama Group service engineers in five, easy-to-navigate screens. A primary display shows a global map indicating every machine at all customer sites the OEM has subscribed to the service. In addition to the display is summary information on machine status and recent OEE performance. A simple search function then allows service engineers to filter by specific end users, locations or machine types for further analysis. At the machine level, OEMs can also view information about machine states, top events, production counts, cycle time attainment, and custom process variables and counters […]

   The merger between Foodstuffs Wellington and Foodstuffs Auckland Co-operatives prompted Foodstuffs North Island Limited to review its software. This process included assessing the various PDF solutions which were already in use by staff, as well as alternative PDF solutions available in the marketplace. Foodstuffs North Island’s goal was to identify and implement a PDF solution that delivered value for money, capability and easy deployment. Their quest led them to Nuance Power PDF. “As a result of the merger we discovered that staff were using a mix of software particularly when it came to PDF solutions. These included various versions of Adobe Acrobat, Nuance PDF Converter, PDF Create and a whole host of other PDF software. Supporting all these PDF solutions was untenable and we needed to identify the best PDF fit for our people,” explained Rachael Butterworth, Foodstuffs North Island, Software Asset and IT Administrator. One of the key criteria the chosen PDF solution had to deliver was value for money. “We have a large number of finance staff who are our primary users of PDF software, so we needed a solution that was monetarily viable given the quantity of licenses required. We looked at the free PDF software available but it lacked functionality. This was also true for many of the cheaper PDF products on the market. “Some of the other solutions we looked at were cloud based and required both a license fee and an annual subscription, making them an expensive option. So we focused on non-cloud options and zeroed in on Nuance Power PDF. This solution was highly competitive. In fact, after examining costs we found that Nuance Power PDF was up to 80% cheaper than some of its competitors,” said Rachael. However, while Nuance Power PDF was cost competitive, Rachael was also keen not to […]

Primary sector and manufacturing employees may find themselves with some interesting new colleagues in the next few years as researchers develop robots that can be trained to work alongside people in factories and the great outdoors. A two-year, $2m project funded by the Science for Technological Innovation National Science Challenge Board is examining how next-generation robots can work with humans in a safe and flexible manner. Researchers will focus on developing robots to work in small-scale manufacturing and unforgiving outdoor environments. Such technology could become a global specialty of New Zealand robotics businesses, with great export opportunities and long-term solutions for the country’s economic needs. The interdisciplinary research programme involves robotics experts from Lincoln Agritech and Scion, as well as researchers and PhD students from the universities of Auckland, Canterbury, Massey, Otago, Victoria and Waikato. The programme is laying the groundwork for follow-up projects over the next few years that will focus on making New Zealand a competitive country for the production and use of robots in small-scale, flexible manufacturing businesses and challenging environments such as those found in agriculture and forestry. “We will advance the science required for a new generation of industrial robotic solutions,” says Lincoln Agritech Group Manager in Precision Agriculture, Dr Armin Werner. “These robots can provide enormous benefits to the primary and manufacturing sectors. Both industries require fast adaptation to different products and markets, and constant responsiveness to changing outdoor environments. “The robots can assist with complex tasks such as pruning tree or vine crops, safely felling trees on steep slopes or assembling small batches of appliances on demand.” To develop the technology, researchers will investigate how sensors and artificial intelligence can allow robots to perceive and understand their surroundings, flexibly handle new situations through learning or training by humans or other robots, and work […]