Manufacturing Technology

AI challenges revealed in book

The Future Computed: AI and Manufacturing is an in-depth look at the challenges and opportunities of AI and how it’s transforming the manufacturing sector. Interviews with customers, policymakers, labor representatives and Microsoft experts shed light on how AI is driving efficiencies, enabling products and services, and allowing for safer workspaces. The book also offers a timely look at how society can respond to some of the challenges this new technology creates, and the need to develop new laws and regulations to address workforce disruption and develop AI in an ethical and responsible manner. A free download of the book is available at The Future Computed microsite, where you can also find other interesting content from the book (e.g. customer videos, case studies, and executive summary).

The sense test

~ How human senses are revolutionising industrial robots ~ As season two of the critically acclaimed TV show Westworld ended in summer 2018, the conversation around what the robot of the future will look like continues. While many believe we will have human-like robots soon, such as those depicted in sci-fi blockbusters like Blade Runner, it will be functionality that dictates the appearance of these machines. Here, John Young sales manager at industrial parts supplier EU Automation, explains how allowing manufacturing robots to see and feel is enabling them to step out of the cage. When we think of robots, we often think of either clunky metal frames that complete menial tasks or something so human, it is almost indistinguishable to the person standing next to you. Both appearances have their uses though, whether it’s for picking, packing and palatising in a manufacturing plant, or entertaining guests at an amusement park. Traditionally, robots have been large and noisy pieces of equipment, often posing potential safety risks to the workforce. A new breed of collaborative robots has changed this though, allowing machines to work side-by-side with human employees. This type of robot is now becoming increasingly commonplace on the plant floor, revolutionising the manufacturing process. In a study carried out by the University of Tennessee’s Knoxville Global Supply Chain Institute, robotics was identified as one of the biggest supply chain disruptors. Paul Dittmann, executive director of the Global Supply Chain Institute and author of the paper, said: “Robotics have been around for more than 50 years, but they have become dramatically more dynamic in the last five. They are no longer stationary, blind, expensive and unintelligent, but can work alongside people and learn as jobs change.” The evolution of the humble robot One of the biggest advances in robotics […]

HandySCAN 3D scanner meets Boeing’s requirements

Creaform, the worldwide leader in portable 3D measurement solutions and non-destructive testing (NDT) solutions, has announced that its HandySCAN 3D metrology-grade 3D laser scanner can now be used for recording physical attributes of aircraft dents and blends on all models of Boeing commercial airplanes. Boeing has released a service letter with guidance on the use of 3D scanners for measuring dents and blends on airplanes. The SmartDENT 3D solution and the flagship HandySCAN 3D scanner were used in the process of guiding Boeing’s quality requirements for the service letter. “Creaform is proud to see leaders such as Boeing, turn to 3D scanning solutions for surface defect inspection. With SmartDENT 3D, our goal is to provide the most accurate damage assessment to our customers, so they can make informed and safe decisions, while getting their aircraft back flying with minimal down time,” said Jérôme Beaumont, Global NDT Business Manager at Creaform. Overview of SmartDENT 3D benefits: Speed: 80 times faster than the pit gauge technique. It is the fastest and most reliable aircraft surface damage inspection tool available on the market. Metrology-grade measurements for aircraft maintenance: The scanner is accurate to 0.025 mm (0.0009 in.) and has a resolution of up to 0.100 mm (0.0039 in.) with high repeatability and traceable certificate. Intuitive pass/fail assessments: With its intuitive design and real-time software visualization, Creaform’s NDT solutions ensure short learning curves and minimal operator experience influence on the accuracy of results. Live visualization and portability: Weighting less than a kilo, the handheld scanner is the perfect tool for work in hangars or directly outdoors. Users can easily perform 3D surface inspection of any part of an aircraft on which they would use manual techniques—including on and under wings. In addition to complying with Boeing’s service letter, Creaform HandySCAN 3D scanners are listed […]

Container deposit system solution to Australia’s war on waste

Adelaide-based technology and engineering company SAGE Automation is increasing production of its smart container deposit systems on the back of increased demand from Queensland. The machines were developed by SAGE Automation and the University of South Australia for South Australian company Container Deposit Systems(CDS) to help decrease Australia’s landfill. South Australia has led the country in recycling, introducing a container refund scheme in 1977, but other Australian states have only just begun to refund bottles and containers. Since Queensland launched its Containers for Change scheme in November 2018, CDS has recorded a rise from 32,000 to 230,000 containers per day through its 16 Semi Auto Return Terminals (ART) at private recyclers across six sites. The terminals allow customers to return deposit cans, plastic bottles and glass in any condition for a 10c-per-container refund. More than 344 million containers have been returned to date since the scheme commenced late last year. The ARTs identify and sort containers by integrating Industrial Internet of Things (IIoT) technology and a vision counting and sorting system developed by SAGE over two years. A recycling depot employee loads the mixed containers onto a vision and sorting system hopper that uses advanced vision technology to count up to 350 containers per minute without the need for coding or labelling. The containers are counted in real time for a predicted refund sum that customers can view on a TV screen at most facilities. Conveyer belts, electric motors and spinning discs sort the containers by separating common recyclables like metals, plastics and glass. The machines have seen thousands of images of containers and can identify different container types, including unwanted materials. The containers are ready to be recycled once compressed air pushes them into specific categorised cages. The entire process takes only a few minutes and a refund receipt […]

Callaghan Innovation support for innovating business

A new tool for start-up businesses will encourage innovation, says BusinessNZ. Chief Executive Kirk Hope says innovation is critical for businesses to stay competitive and attract new customers. “But research & development is costly, and many New Zealand businesses struggle to gain the investment needed to develop new products, services or processes. “The Scale-UP NZ platform launched by Callaghan Innovation today will help innovating companies to network, gain introductions, collaborate and attract investment.” Mr Hope said the digital platform, modelled on successful platforms in other countries, would help businesses and the New Zealand economy benefit from their intellectual property and creative ideas.

businessman is working on tablet and using smart phone in office

Safe and sound – Is your smart factory secure?

Alarms, cameras, locks and fences are all commonly recommended to keep burglars out of homes. Obtaining clear guidance for securing your smart factory isn’t quite as easy to come by. Here Jonathan Wilkins, marketing director at obsolete industrial equipment supplier, EU Automation, discusses smart factory security and what manufacturers should consider when protecting their facility. In a connected factory, manufacturers have access to a constant data stream from the shop floor, commercial operations and supply. The Internet of Things (IoT) generates a huge amount of data, gathered from machines and components, which can be accessed and analysed remotely. Though it brings a facility a number of advantages, connectivity also introduces a vulnerability in terms of cyber-security. With information technology (IT) and operational technology (OT) more closely connected than ever, systems are more vulnerable to attackers. The risk is increased by remote access or third-party access. According to Dark Reading magazine, the second most cyber-attacked industry after healthcare is manufacturing. With high profile ransomware attacks such as WannaCry disrupting large companies such as Honda, manufacturers know they must be vigilant. In the manufacturing industry, cyber-crime is usually a type of data theft, ransomware or data manipulation. Hackers can modify procedures to disrupt production processes, gain access to private patent data or cause system downtime, all of which can cause serious losses to a company. Engineering businesses must ensure that their operations, data and valuable intellectual property (IP) are protected. Businesses need to understand the limitations of their own capabilities and systems to form a well-rounded cyber-security strategy. For example, legacy equipment can be a target for cyber-criminals. Old equipment was not designed to be connected to the internet, which means that cyber security was not a priority during its design. Industrial control systems as well as programmable logic controllers (PLCs) have […]

What do your motors really do?

In 1969, the first home security system was born, consisting of four peepholes and a camera that could be moved to look through any of them, broadcasting the images to a monitor. Nowadays, we can now stream and view a feed of our home security cameras on our mobiles, giving homeowners greater piece of mind. Here, Markus Brettschneider, of ABB’s food and beverage program, explains how food plant managers can add a similar level of connectivity to retrofit most motors with smart sensors to bring their plants to the digital age. Industry as a whole is utilising technologies and solutions enabled through the industrial internet of things (IIoT). Gartner predicts that 25 billion devices will be connected to the internet of things by 2020, with some agencies predicting even double this amount. This presents plant managers with a conundrum. Most food manufacturing and processing plants currently have motors powering essential equipment such as mixers, conveyors and packaging machines. These motors are just motors and do not play in the same league as the other intelligent devices in their factories. With years of service often left in the motors, it’s difficult for plant managers to justify replacing motors that work effectively for the sake of an upgrade with any smart features. However, there are alternatives to a complete overhaul in order to connect motors to the IIoT. Instead of investing in new, more intelligent or smart equipment, plant managers should invest in sensors that provide similar functionality to connected devices. For example, ABB offers smart sensors, which can be fitted to almost any standard low voltage induction motor. The pocket-sized sensor, dubbed ABB Ability Smart Sensor, is directly attached in a couple minutes to the motor’s frame, without wiring. By using sensors that feed performance data to the cloud through a […]

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3D printing the next generation of machinery

By Ben Murton and Associate Professor Don Clucas, Dept of Mechanical Engineering, University of Canterbury While metal 3D printing is regularly used for components such as brackets, rocket parts and turbine fuel nozzles, it is rarely used as the major manufacturing process for an entire mechanical system. In a world first, students from the University of Canterbury developed an operational 3d printed titanium ethanol fuel injected internal combustion engine, showcasing the possibilities and limitations for the process. The team took their engine to Singapore and won the innovation award at the Shell Eco-Marathon event, a global competition on for students to compete with highly efficient vehicles. This was all done in one academic year, so a highly accelerated design process was required. To test and visualise ideas quickly, concepts were modelled and refined using cheaper and easier to post-process polymer 3D printing. The titanium parts that were optimised for efficiency, not machining constraints, were then printed and post-processed. Post processing proved to be the biggest headache. It is often said that 3d printing can create anything, but in reality it has its limitations and drawbacks. An example is the almost organic shape of the cylinder head that required little post processing, while the rather basic cylinder required complex support material. Using a laser sintering process that melts and fuses layers of very fine titanium powder has its complications. Thermal contraction of thin features would distort the part, much like MIG welding distorts steel, so support material is required. Removing the support required many hours EDM wire cutting, machining, and finally sand blasting. Before and after cutting the part off the build plate, thermal stress relief was required. Good Design for Additive Manufacture, DfAM, was essential to avoid or reduce the support material, ease support material removal, and reduce distortion. […]

Transforming the manufacturing industry with Internet-of-Things

By Mike Russell COO Central Innovation In a highly competitive global marketplace, businesses are searching for and adopting revolutionary technology and processes to stay relevant. According to the latest IDC Worldwide semiannual Internet of Things Spending Guide[1], New Zealand shares the second highest position with Australia in APAC region when it comes to the IoT spenders per capita. The report further highlights that the top three industries spending most on IoT solutions in 2018 were discrete manufacturing ($43.9 billion), process manufacturing ($33.2 billion) and utilities ($20.1 billion). With the advent of automation and analytics, manufacturing is moving from mass production to mass customisation. The immense growth of IoT in the industry has resulted in factories being able to extract critical data on operations. By using big data and machine learning they are achieving more efficiency in their workplace as well as enhancing customer experience. Without a doubt, IoT is a clear investment area for the manufacturing industry particularly in the Asia Pacific Region which is among the world’s top regions for IoT adoption and usage[2]. To effectively work with new technologies, businesses must be prepared to think differently, adapt and invest to remain competitive. According to the MBIE report[3], Industry 4.0 is seen both as a threat and an opportunity for New Zealand manufacturers. The ministry believes that Industry 4.0 technologies have the potential to make a type of short run, customised production that will enable more specialisation to become efficient and profitable. This would be especially important for the manufacturing industry where it currently accounts for 12 per cent of New Zealand’s GDP value. This means there is untapped potential for New Zealand businesses to stand out from their competitors in the race to transform their businesses. Business productivity The bottom-line when adopting new technology is that it will […]

Point Pod latest start-up success story

A new innovative product that solves your household power problems has teamed up with Australia and New Zealand’s large distributor just six months after making its market debut. Point Pod finally solves the problem of not having enough power outlets in your kitchen by hiding a pop-up unit beneath your stone or timber bench top. Brisbane builder-turned-entrepreneur, Cameron Singer, developed Point Pod after being frustrated with the limited options on the market. “I developed Point Pod two years ago out of my own frustration of the limited power options available,” says Mr Singer. “After renovating my own house, I was disappointed with what was available to improve access to power for my island bench. There were products online, but they looked so cheap and flimsy in a kitchen we’d spent a lot of money renovating.” With a simple touch, Point Pod’s power points and USB sockets emerge for use. But unlike other power options, it blends seamlessly into your bench top, so it doesn’t comprise your aesthetics. The units are designed for any space where you would use power on a bench top, including the kitchen, bathroom, office and boardroom. After launching in August 2018, Point Pod has today announced its new partnership with Häfele, Australia and New Zealand’s biggest distributor. “I’m excited for Point Pod’s next phase, working alongside Häfele,” Mr Singer says. “Häfele’s commitment to innovation made them the number choice for our distribution partner.” “Häfele brings new innovative products to the market so their customers are always on the cutting edge of what’s available, and we’re excited to be part of it.” “Our distribution agreement gives us access to a larger chunk of the market, but it also means we can focus on manufacturing and developing further products.” Mr Singer says he’s been overwhelmed by the industry’s […]

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