Manufacturing Technology

Workforce robots on the horizon

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 […]

Simcenter 3D advances computer-aided engineering and simulation

Siemens Simcenter 3D, is its flagship environment for multi-disciplinary computer-aided engineering (CAE), with new comprehensive solutions across multiple simulation disciplines. Simcenter 3D is an advanced stand-alone CAE application for analysts and discipline experts that works with data from any CAD source. Because it is built on the Siemens NXT platform, it also works seamlessly with NX CAD. With more enhancements than any previous release, Simcenter 3D, part of Siemens’s Simcenter portfolio of simulation and test solutions for predictive engineering analytics, looks to revolutionise how simulation engineers can help drive design direction in industries such as automotive, aerospace and industrial machinery. This latest release provides topology optimisation solutions that work seamlessly with Convergent Modeling technology to provide comprehensive generative design workflows. These solutions allow for more accurate motion modeling, and more efficient acoustic and structural dynamics simulations. Simcenter 3D now provides expanded support for general purpose nonlinear solutions based on the NX Nastran multi-step nonlinear solver as well as advanced analysis of composites based on LMS Samtech Samcef software. This latest release also delivers several enhancements to improve industry workflows across a wide range of industries, for modeling connections in large assemblies as well as accurate simulation of flexible pipes and hoses. Working seamlessly with NX CAD and Convergent Modeling technology, Simcenter 3D now offers generative design solutions for designers and advanced analysts. For the first time, output from a topology optimisation process can be utilised directly in the design process, without the need to recreate geometry. Furthermore, engineers can now work directly with scanned data or an optimised shape to conduct more detailed simulations to ensure performance. By using Simcenter 3D along with HEEDS software for design exploration automation, engineers are able to fully explore the design space and generate innovative designs that meet more stringent design requirements. New with […]

3D toothbrush made from metal

Zare from Boretto, Italy, has ventured to design a new toothbrush in collaboration with Nussbaumer Design, headed by Christoph Nussbaumer. The result is very unusual – this toothbrush is made from metal. Under the brand name MIO, this 3D-printed toothbrush featuring a timeless design is produced by means of additive manufacturing. One of the technical strengths of 3D metal printing lies in its ability to redefine the function and geometry of products. So it’s hardly surprising that a 3D toothbrush made from metal has a different effect than a common toothbrush. And this holds true even though injection-molded toothbrushes made of plastic have been design objects or years now. When we buy a new toothbrush, today we can find ergonomic designs that combine customisation and functionality, with colors and shapes that are intended to captivate us. Zare’s 3D metal toothbrush goes one step further. In 2013, Zare procured its first 3D metal printer – an M2 cusing from Concept Laser. Thanks to the company’s experience with conventional machining techniques and plastic prototyping, Zare quickly realised the advantages of 3D metal printing, introducing its customers to the new possibilities. Zare breaks the mould Though Zare was already successful in 3D metal printing, the company never really had the idea to create a designer toothpaste made from metal. The objective was to take a normal object of daily use and create a luxury item not yet available that could only be created using additive manufacturing based on its design. In the end the company chose a “customisable” toothbrush made from metal. The production costs didn’t play a decisive role, the focus instead placed on a unique design, exclusivity and user friendliness, in this case ergonomics. At Zare, a company originally from the prototyping sector, these dependencies were ground for a new approach. […]

Tool digitisation delivers immense benefits

Many companies are pursuing different paths as they attempt to realise Industry 4.0. For global electrical engineering manufacturer, Phoenix Contact, the focus has been on integrating digital data about its manufacturing tools to ensure their ongoing integrity and as a step towards creating an increasingly automated manufacturing environment. Phoenix Contact produces over 60,000 different products, including solutions for connection, interface, automation and surge protection. With so many models to produce and the continuous demand for new products, maintaining the operation and integrity of its dies is critical to its ongoing manufacturing success. The dies are used in the production of screws, plastics and metal parts, but also in highly automated assembly machines as well as punching, bending and injection moulding tools. Usually made from hardened steel, the dies can take months to create and are expensive to produce. Phoenix Contact realised that by digitising information about its dies it could create a lifetime digital document on each tool. This would allow it to quickly and easily track the quality of its tools, enhance its manufacturing process, and further interlink systems as it moved towards Industry 4.0. Consequently, all relevant information about each individual die was digitised. The data gathered included the year the tool was produced, material used to construct it, maintenance details, and so forth. It was then incorporated into the overall manufacturing process via the internet so that staff and systems could automatically connect and communicate as well as track and monitor the dies performance, its usage, wear and tear, and to determine its availability in the manufacturing process. Since digitising the information, the benefits for the company have been immense. Dies are now automatically scheduled for maintenance based on usage. Staff and manufacturing systems communicate, and are notified in advance of the required maintenance. The higher-level control […]

Exponential Manufacturing Revolution

Diane Francis Member of Advisory Council at Hudson Institute Kleptocracy Initiative The train to Boston from New York speeds past stunning scenery as well as the blight of abandoned factories, scarred with graffiti. These empty buildings are the remnants of a New England that was the China of the Industrial Revolution based on cheap immigrant labour. Today, its towns languish economically, except for Boston, which is enjoying a resurgence as a technology, pharma, and advanced manufacturing hub. This week, American experts from industry, technology, and policy gathered at a conference in Boston, curated by Singularity University, to discuss the role of tech in manufacturing. America remains a manufacturing powerhouse, as well as the world’s pre-eminent technology nation, but marrying the two will take time. In global terms, the industrial sector represents one-third of all global economic output and represents half of the world’s energy consumption and renewables. “This year, offshore wind power generation matched the cost of natural gas power plants in Europe,” said Singularity’s energy expert Ramez Naam. “In windy parts of the world, wind power is cheapest, and in sunny parts of the world solar is.” In solar, record low prices were reached this year too. A major contract in Dubai at 2.91 U.S. cents per kilowatt hour, the world’s lowest — Ontario’s prices average 8 cents per kilowatt hour. India just completed the world’s largest solar farm (4.5 U.S. cents per kilowatt hour) and its federal government intends to have only electrically-powered vehicles by 2030 – completely bypassing fossil fuels. As these industries scale, costs plummet for solar panels and turbines. China is converting to renewables rapidly, but has also earmarked half a trillion dollars to become the world’s advanced manufacturing leader. This is a major pivot, necessary in light of the fact that cheap labour, in […]

Rockwell Automation CEO discusses future of Industrial IoT

Blake Moret shares insights on IoT and Industrial Productivity at Cisco’s 2017 Internet of Things World Forum Blake Moret, president and CEO of Rockwell Automation, spoke on Internet of Things (IoT) adoption and its impact on industrial productivity, sharing insights with more than 1,200 business leaders at Cisco’s IoT World Forum in London. As the industry’s only company solely dedicated to industrial automation and information, Rockwell Automation is uniquely positioned to understand the challenges and opportunities associated with harnessing the future of smart manufacturing. As Moret described, the positive outcomes associated with IoT will continue to accelerate as organisations progress from pilot or proof-of-concept IoT projects to scalable IoT deployments. According to the Global IoT Decision Maker Survey published by International Data Corporation (IDC), nearly one-third (31 percent) of those surveyed have already launched IoT solutions, and another 43 percent are looking to deploy solutions in the next 12 months. Rockwell Automation is seeing a similar trend in its deployment of IoT solutions, and continues to increase its number of pilots across industries, applications and geographies. “Manufacturers and industrial operators are discovering practical ways to apply IoT across their operations, and they’re deriving measurable business value as a result,” Moret said. “Combining IoT technology and expertise in specific industrial applications enables better collaboration, faster problem-solving and increased productivity.” Moret referenced several factors driving the adoption of industrial IoT and connected operations, including lower cost of computing and connectivity, and the convergence of information technology and operations technology. Moret explained how a connected enterprise that adopts IoT technologies can generate better insight into industrial operations and deliver greater value by providing the right information at every level of their business through scalable analytics. He cited Great Lakes Brewing Co. as a Rockwell Automation customer that is adopting scalable analytics to improve visibility and productivity for different parts of their operations. The 2017 IoT World Forum explores the impact of IoT on business, […]

Exponential Manufacturing Revolution

Diane Francis, Member of Advisory Council at Hudson Institute Kleptocracy Initiative The train to Boston from New York speeds past stunning scenery as well as the blight of abandoned factories, scarred with graffiti. These empty buildings are the remnants of a New England that was the China of the Industrial Revolution based on cheap immigrant labour. Today, its towns languish economically, except for Boston, which is enjoying a resurgence as a technology, pharma, and advanced manufacturing hub. America remains a manufacturing powerhouse, as well as the world’s pre-eminent technology nation, but marrying the two will take time. In global terms, the industrial sector represents one-third of all global economic output and represents half of the world’s energy consumption and renewables. “This year, offshore wind power generation matched the cost of natural gas power plants in Europe,” said Singularity’s energy expert Ramez Naam. “In windy parts of the world, wind power is cheapest, and in sunny parts of the world solar is.” In solar, record low prices were reached this year too. A major contract in Dubai at 2.91 U.S. cents per kilowatt hour, the world’s lowest — Ontario’s prices average 8 cents per kilowatt hour. India just completed the world’s largest solar farm (4.5 U.S. cents per kilowatt hour) and its federal government intends to have only electrically-powered vehicles by 2030 – completely bypassing fossil fuels. As these industries scale, costs plummet for solar panels and turbines. China is converting to renewables rapidly, but has also earmarked half a trillion dollars to become the world’s advanced manufacturing leader. This is a major pivot, necessary in light of the fact that cheap labour, in an era of technology, is no longer a competitive advantage. “China has launched the Artificial Intelligence Institute and its companies are buying companies globally in this space,” said […]

A game-changing material

Customisation is the name of the game for Utah Trikes, a producer of trikes, quads and custom wheelchairs. President and CEO, Ashley Guy, said from the very beginning the company was all about personalisation. “We started making our quad using existing frame platforms and built custom two-wheel drive rear ends that we’d add on and effectively turn the trikes into quads. That grew into something where suddenly everybody who wanted something customised came to us.” These custom lugs, made with Stratasys FDM Nylon 12CF, are painted red after emerging from the tumbler with a smooth, polished finish. Customer Needs Drive Innovation But customisation has its obstacles, namely time and cost. “The production run might only be 100 parts and it’s hard to get your cost down with such a small run,” said Guy. Utah Trikes’ next step was trying to solve its manufacturing issues. “We have some CNC machines we ran pretty much nonstop,” Guy said. “But this was always a hassle without committing to jigs and fixtures, which meant a lot of man hours to prototype.” Also, as the parts became more complicated it became harder and harder for Utah Trikes to outsource. What Utah Trikes needed was the ability to make prototype pieces they could actually test, and that would be both cost and time efficient. About this time, 3D printing showed up on Guy’s radar. “I was intrigued but had no idea what I was looking for. When we heard about Stratasys Fortus 3D Printers, we knew we had a true production tool that could make real production parts.” FDM Nylon 12 CF A Game-Changer “The FDM Nylon 12CF is fantastic. It’s changing everything for us,” Guy said. He cites the strength of the material, as well as its soluble support as game changers. Additionally, “We can take […]

SEMICON -Industry 4.0 no longer hype

Disruption and the Value of Digital Transformation in Manufacturing; Learn More at SEMICON Southeast Asia 2017. SEMICON Southeast Asia 2017, held at the SPICE arena in Penang on 25-27 April, is Asia’s premier showcase for electronics manufacturing innovation. KUALA LUMPUR – At SEMICON Southeast Asia 2017, Dr. Chen Fusen, CEO of Kulicke & Soffa Pte Ltd, Singapore, will give a keynote on the digital transformation in the manufacturing sector. Chen believes that Smart Manufacturing, or Industry 4.0, is no longer hype, but real and Asia needs to get on board sooner rather than later. SEMICON Southeast Asia (SEA) 2017, held at the SPICE arena in Penang on 25-27 April, is Asia’s premier showcase for electronics manufacturing innovation. “Digital transformation has proven to provide solutions for addressing challenges in the manufacturing industry but there is still the issue of acceptance as well as lack of skills and knowledge that needs to be addressed,” said Chen. “With disruptive technology changing our world, I expect that more companies will see the value of their investments realised as this technology accelerates the creation of more individualised products and services.” Dr. Hai Wang from NXP Semiconductors Singapore Pte Ltd, Singapore agreed that more consumer-related innovations would stem from digital transformation as demand for solutions that provide efficiency and security increases. “At NXP, we look at developing advanced cyber security solutions for the automotive industry, such as tracking and analysing intelligence around connected and automated vehicles, which will help to counter any adverse threats in real time. These innovations are real and will soon mark a shift in the future of automation and manufacturing. It is vital that we embrace the change and adapt accordingly,” he said. Other speakers at SEMICON SEA also feel strongly about the importance of Smart Manufacturing and digital transformation. David Chang […]

Innovative zero-gravity arms recognised by construction company

Headquartered in Hong Kong, Gammon Construction is one of SE Asia’s leading construction companies, with an annual turnover of US$2.5bn, and is a keen adopter of new technology with a focus on adding value for its customers through innovative and sustainable solutions. With over 8000 employees, the engineering and construction company, like others in the Hong Kong construction industry, has long faced manpower shortages, together with an aging workforce. Consequently, in an effort to lure talented new workers and to reduce the workload of its employees, the company recently invested in two sets of “zero-gravity arms” (Zero G Tool Arms) from Sigma Ergonomics, one of Australia’s leading providers of ergonomic systems to a wide range of industries. Manufactured by US company Ekso Bionics, the innovative mounted exoskeletal system functions without the need for power, allowing workers to comfortably operate heavy tools including impact drills, chipping hammers and grinders for extended periods. With the zero-gravity arms shouldering the weight of the equipment, workers are not affected by the strain and fatigue caused by repetitive tasks such as drilling, tiling, chipping and grinding. The Ekso Bionics Aerial System, to which the Zero G system is mounted, is designed to increase safety and productivity while working from an elevated work platform (EWP). As well as eliminating the risk of dropping heavy tools from heights, the system significantly reduces the risk of injury from heavy tool usage and awkward body position. In a recent direct comparison with an Access Work Platform (AWP) at a height services installation, the Zero G system improved the productivity of the drilling work task by over 50% while reducing worker fatigue and improving safety and efficiency. Thomas Ho, Chief Executive of Gammon Construction, is a passionate supporter of innovation and highlights the Zero G system as one of the […]

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