Manufacturing Technology

Networked Manufacturing

– Dieter Adam, CEO of the NZMEA The next wave of technological developments, described as Industry 4.0, have the potential to substantially change the nature of manufacturing, around the world and in New Zealand. Though its future and realities are uncertain, it could represent huge opportunities for those who can leverage technology, and risks if we cannot keep up. Take networked manufacturing. At the core of this is the idea that the physical elements on the factory floor – machines, tools, transportation systems and products are all networked; they can send data to a central control point and to each other and receive instructions from a central control point and from each other. Centralised monitoring and control of production equipment is not new – the interconnectivity of all elements and the potential to process and learn from large amounts of data, however, is new. This technology could give manufacturers the ability to monitor and record the performance of pretty much any tool or machinery on a production line in terms of each individual action. Beyond the immediate quality control, this will allow far-reaching retrospective analyses of potential mechanical failure when the cause of a vehicle accident is investigated, for example. Other uses could include fully autonomous local logistics, self-managing the flow of materials through a process line and factory, or physically attaching further-processing instructions to semi-finished products on a line (via RFID) to allow automatic variations within the production process. It will provide more flexibility to use input from other parties to define customisation without having to manually change tools or adjust production lines. At the macro level (systems level), Big Data systems will allow the analysis of ever more complex sets of data to identify and predict the occurrence of (rare) events. One of the most potent Big Data […]

Taking steps to protect connected industrial infrastructure

By: Gavin Coulthard, Systems Engineering Manager for Australia and New Zealand, Palo Alto Networks Networked devices and computer-controlled machines are nothing new in the manufacturing industry, but the rise of the Internet of Things (IoT) is seeing an unprecedented number of devices connected to the internet for monitoring and control purposes. There are applications for IoT devices in almost every industry, and the manufacturing sector has much to gain from this technology. In many ways, the industrial control and automation systems commonly used in manufacturing processes have, for a long time, acted as precursors to the connected devices that are now available to consumers. However, today’s development of IoT technology delivers new capabilities for businesses as well as individuals. These connected devices and systems can offer better management of industrial control systems (ICS). IoT technology supports a granular quality of control and monitoring data, which can benefit supervisory control and data acquisition (SCADA) systems or distributed control systems and, in fact, any industrial automation system. We’re talking about large volumes of sometimes very complex data. When used well, IoT technology provides an extremely useful tool. While these new capabilities can lend enormous value to manufacturers, they also come with new problems. First among these is the issue of information security. Mixing operational technology systems and information technology systems by way of IoT devices increases an organisation’s threat surface and opens up new ways for hackers to breach sensitive organisational networks. In some organisations, this can result in data and financial losses. But for manufacturers, it can lead to infrastructure and reputational damage, and even open up the possibility of personal harm to workers. In 2010, for example, centrifuges at Iran’s Natanz nuclear facility failed due to malware called Stuxnet. Now considered a cyber weapon, Stuxnet has since been followed by […]

Use the super computer in your pocket for new levels of productivity

Anyone with a smartphone or tablet now can connect securely in an industrial setting to access performance metrics and data analytics. By Kyle Reissner, mobility platform leader, Rockwell Automation You can use any digital device to easily access performance metrics and data analytics from your plant floor and machines. How are you using that freedom? Your smartphone is now as powerful as your desktop. That mobility is more than viewing a webpage or report on your tablet; it’s a fundamental shift in how we live our lives. Seventy percent of us carry a smartphone or tablet into the office. We are mobile. Yet many of us still live as if the world is flat. You know the analogy. For thousands of years people lived like they would fall off the edge of the earth if they ventured too far from what they knew. Then we realized the world is a sphere, and that opened a world of possibility. Since the 1980s, we’ve used the Purdue Enterprise Reference Architecture to define clear layers between systems. Our first shot at mobility was the replicate a web browser in a Palm Treo. It was a good start, but it fell short of the ultimate user experience. Some people are using the latest devices to extend 20-year-old technology. That type of mobility is resulting in very small increases in productivity, in the range of 1 to 2 percent. I suggest a loftier goal for mobility —10 percent — and for everyone in the plant, not just one or two people. It’s possible because we now have the technology that lets people do things they couldn’t do before while reducing the cost of curiosity to literally zero. Now, anyone with a device can connect securely, expand their area of influence, deploy a system more quickly […]

Making electronics safe with pervoskites

In the picture:Blue ceramic capacitor A team of scientists from Hokkaido University and the multinational electronics company TDK Corporation in Japan has developed a method to improve the insulating properties of the oxynitride perovskite SrTaO2N for potential use as a ceramic capacitor. Ceramic capacitors are used in a wide variety of electronics, ranging from computers and mobile phones to telecommunications transmitter stations and high voltage laser power supplies. Capacitors act, in a way, like batteries. They are “dielectric” – they act as an electronic insulator in which an electric field can be sustained with minimum loss of power. Their dielectric properties allow them to store electricity and then release it. One of the most widely used ceramics in capacitors is lead zirconate titanate, but it is hazardous to the health and the environment once it’s disposed. Scientists are trying to find other less hazardous ceramic materials for use in capacitors. Perovskite oxynitrides – cheap and easily fabricated materials with a distinctive crystalline structure – are particularly promising. But ceramics manufactured from these materials need to be made denser to improve their insulating properties. This is usually done by applying intense heat; a process called “sintering”. However, sintering the material can lead to a change in its chemical composition, turning it from an insulator to an electrical conductor. The researchers sintered the perovskite powder SrTaO2N at a temperature of 1723 Kelvin (1450° Celsius) for three hours. They then “annealed” the material by heating it with flowing ammonia at 1223 Kelvin (950° Celsius) for 12 hours and then allowing it to slowly cool. They found that the surface of the material after this process (but not its interior) displayed an important dielectric property called “ferroelectricity”. This was the first time that a ferroelectric response has been observed on oxynitride perovskite ceramics, they […]

Motion Analyzer web tool helps design control systems

Rockwell Automation has rebuilt Motion Analyzer software as a Web tool. The tool offers new user-friendly features and a vastly expanded product catalog to help engineers more easily specify, design and validate complete motion control systems. The Motion Analyzer Web tool is cloud-based, allowing users to access, update and collaborate on projects stored in a single location, reducing version control issues and the need to share project files back and forth. A cloud-based platform also means users are no longer limited by the processing speed of their computers when designing systems for more complex applications. The tool’s new browser-style format allows users to filter, review and compare products and general pricing, similar to search capabilities on popular e-commerce sites. “Incorrectly sizing a motion system not only generates unnecessary costs in wasted engineering time and re-stocking fees, but it can greatly slow a machine’s time-to-market,” said Gavin Black, product manager CompactLogix, SLC, Kinetix Motion, Rockwell Automation. “The latest Motion Analyzer release is an evolution of the platform that is more collaborative, expansive and easy to use. When engineers can quickly create and examine complete motion control systems within a single platform, they can spend more time innovating and improving their machines.” The Motion Analyzer Web tool provides machine builders access to a wider range of motion control products than ever before. It now incorporates products from nine Rockwell Automation PartnerNetwork Encompass product partners, including STOBER Drives, NIDEC-SHIMPO, item North America, Tolomatic, Nook Industries, WITTENSTEIN, Exlar Corporation, Bonitron and Elwood Corporation. “Collaboration between various disciplines among machine builders and automation solution providers is critical to lower the Total Cost to Design, Develop and Deliver equipment,” said Clayton Webber, STOBER Drives. “Having mechatronic solutions up-to-date in the cloud establishes Motion Analyzer as a differentiator in machine design. STOBER and Rockwell Automation are striving […]

IIoT and design engineers in the future

The Industrial Internet of Things (IIoT) is furthering its reach into engineering and design. Connected machines will give plant engineering operations the opportunity to identify points of inefficiency, improve upon those points, and in turn, improve profitability. To further discuss how IIoT is impacting work for design engineers, Mark Duncan, segment manager of material handling and packaging machinery for Schneider Electric’s industry business. In the future, Duncan believes engineers will have to focus on existing machine designs and their communications standards, and monitor those standards as they progress. Some examples of this include Internet protocols such as Ethernet, which promote machine-to-machine connectivity, more plug-and play-use, and a smoother transition into a plant environment. Duncan also believes that, as they look to the future, design engineers must be cognisant of the developing standards in machine-to-machine communication. “We have a customer that makes a machine for the coffee industry, and that machine is really built to be modular, connected, and is also built to be self-aware of its own capability and how it’s performing,” he said. “It’s also a safe machine, designed with safety built in. It communicates with other machines in a production line.” An example of this would be the material and product that comes into the machine, such as the one Duncan describes. That product would be processed by the machine, put into a package, and then moved to another machine, with the product cartons eventually taken to a palletizer. Using communication standards, this complete process is simpler than previous practices, where end users would have to reprogram each machine, allowing the machines to work together. Duncan expects that because of machine language standards (such as those for packaging machines using a language called PACKML) machines will be able to instantaneously communicate information in consistent data sets that could […]

ETRI presents a blueprint of the ‘5G future’

A 5G future is no longer a distant one, but an upcoming reality. High quality videos of more than 10Mbps can be served simultaneously to 100 users even in a train running at up to 500km/h. People can experience data rates that are 100 times faster than currently available technologies. 5G is the next generation wireless technology that would provide even faster data rates, even lower delays, and even more devices connected than 4G. Accordingly, distinct and differentiated applications are expected in 5G. ETRI’s “future SNS” is a kind of trial service model to apply 5G technologies that provides dynamic user-centric connection to neighbouring people, things and spaces. It is characterised by instant content-sharing between users, communication with neighboring things, and Giga-bps(Gbps)-grade video applications in vehicles. 5G core technologies demonstrated by ETRI include the following: — MHN (Mobile Hot-spot Network) is a mobile backhaul technology that provides high-speed Internet access of Gbps in vehicles at speeds of up to 500 km/h (e.g. KTX in Korea). Almost 100 passengers can watch videos of high quality simultaneously. — ZING is a near-field communication technology that enables mass data to be transmitted with 3.5 Gbps data rate between neighboring devices within the radius of 10cm. — Single-RF-Chain compact MIMO technology enables a single antenna to simulate the effect of multiple antenna. It can reduce antenna volume and cancel inter-antenna interference in a multi-antenna system. — Millimeter wave (mmWave) beam switching technology provides fast switching of radio beams to mobile users, and therefore allows seamless Gbps-grade service in mobile environments. — Mobile Edge Platform (MEP) is a mobile edge cloud server on vehicles that enables passengers to enjoy customised Gbps-grade content and connects them with neighbours, things and spaces. It provides user-centric services. — In-band Full Duplex technology can transmit and receive signals simultaneously […]

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