Smart Manufacturing Today

The future of thermoplastics

There are two major types of resin used in the production of composites — thermosetting and thermoplastic. Thermosetting resins are currently the most common, but as composite use expands, thermoplastic resins are increasingly being explored. Thermosetting resins are hardened via curing, using heat, to form heavily cross-linked polymers with insoluble or infusible rigid bonds that will not melt on exposure to heat. On the other hand, thermoplastics are branches or chains of monomers that soften when heated and solidify once cooled — a reversible process with no chemical bonding. Put simply, you can re-melt and re-form a thermoplastic, but not a thermoset. Why thermosets rule Thermosetting resins, such as epoxies or polyesters, are popular for composite production because their low viscosity helps achieve good penetration into the fibre network. This allows for the use of more fibres and increases the strength of the final composite material. The process for a thermosetting resin begins, in the pultrusion process, with the fibres being immersed in resin, which are then pulled into a die where heat is applied. This starts the curing reaction that converts the low molecular weight liquid resin into solid three-dimensional network structure, locking the fibres into this newly formed network. Because most curing reactions are exothermic, once the reaction has begun it will readily propagate, making thermoset production easily scalable. Once set, the three-dimensional structure locks the fibre in place and gives the composite its strength and rigidity. The rise of the thermoplasticThermoplastics and thermoplastic composites have been around for some time, especially for short fibre applications. But new attention is being drawn towards thermoplastics, due to the rising need for additional light weighting without the loss of structural stability, especially in the automotive industry. One specific example is the potential to use thermoplastic composite to reduce the weight […]

Can we be more productive?

By Ian Walsh, Managing Director, Intent Group Over the past 50 years, New Zealand has been on a negative GDP trajectory versus the OECD, sliding from 5th place to 22nd! The top 10 countries average 60% more productivity per person per capita in US$ than we do, and this gap has been widening since the mid 1980’s.* The general consensus is that we work hard, and the statistics say we work more hours than most. Clearly this is the harder not smarter argument. Perhaps Sir Paul Callaghan captured it best when he said, “In New Zealand we sense, somehow we are not as prosperous as we would like.” Without highly productive businesses we will not be able to generate the income to invest in human and physical capital, to create the society and country we aspire to. So why are we less productive? There has been a lot of research over the years, with the traditional arguments being that our costs are higher as we are further away from market. The research, however, shows that we should be 20% above the average** and playing in the top 10, but we are not. This is due to: Weak international connections. New Zealand firms face reduced access to large markets and limited participation in global value chains, where the transfer of advanced technologies now often occurs. Underinvestment in “knowledge-based capital”. In particular, R&D undertaken by the business sector is among the lowest in the OECD, reducing the capacity for “frontier innovation” and the ability of firms to absorb new ideas developed elsewhere (“technological catch-up”). The quality of management in New Zealand is low, which decreases the productivity gains from new technology. I find these outcomes interesting, but not surprising. 90% of NZ businesses are SME’s who can’t afford HR or a training manager, let alone an innovation manager! Most investment is managed by the entrepreneur who started the […]

Robotics tutor creates real time map of PPE demand

As part of his volunteer work for ShieldsUp, an organisation established at the start of lockdown which called on volunteers to 3D print personal protective equipment (PPE) to fill the shortage gap, WelTec tutor Frank Beinersdorf has developed a real time map of how many, and where, protective shields are needed across New Zealand. Frank’s map is what Shieldsup uses to determine how many shields need to be made, and provides information to the many volunteers tasked with delivering the equipment. Using various icons, the map displays priority of orders, what orders are ready to go, or are on the way, and a heat map of what is still needed. There is also a visual chart to demonstrate demand over time and a chart tracking Covid cases in New Zealand. The map and information can be found here: https://beinerf.github.io/. “Frank’s work became invaluable as we grew beyond lists and text,” says Tim Carr, ShieldsUp founder. “What he did in regard to visualising a rapidly growing data set has allowed us to see where resources were needed and demand was growing.” ShieldsUp is a community driven initiative, conceived from the outcry of medical and emergency responders facing COVID-19 head on, as they put their own health at risk in their jobs to help protect others, often without the personal protective equipment they so desperately needed. As well as providing information on numbers and location of PPE required, Frank has also converted the data into useful quick facts, kept up to date real time. For example, on Tuesday May 5th, over 18, 000 shields were still needed, 22 242 were wanted and 16, 521 had been made and delivered by 254 volunteers across New Zealand. In the spirit of community from which ShieldsUp was created, Frank included fun facts in his data […]

What is Generative Design?

At a high-level, Generative Design is relatively simple. It is a capability of CAD applications that autonomously generates a number of design alternatives given a set number of constraints. This can be done without an engineer’s guidance or interaction, freeing them up for other tasks. Once complete, the engineers can choose which designs they want to explore more completely. In all, this accelerates the design process without detailed attention from the engineer. Related Products Generative Design Tools in Solid Edge Innovation Through Generative Design Generative Design ebook PDF Download How Generative Design and Additive Manufacturing Work Together Mother Nature’s Inspiration in Generative Design Projects Generative Design in NX Generative Design and topology optimisation Generative Design supports key capabilities for performing structural simulation and removing load-weight from empty area in materials. Siemens NX 12 generative design software embeds topology optimisation powered by convergent technology which enables unified 3D modelling capability on combinations of Facet and B-rep data. This results in lighter components without sacrificing design intent or integrity. Empowering engineers with Generative Design and facet modelling Generative Design is an cad engineering software function in which a designer collaborates with artificial intelligence algorithms to generate and evaluate hundreds of potential designs for a product idea. The Generative Design process starts with defining the goals and constraints of the project. These include, but are not limited to, design parameters such as: ⦁ product size or geometric dimensions ⦁ permissible loads and operating conditions ⦁ target weight ⦁ materials ⦁ manufacturing methods ⦁ cost per unit Benefits of building with Generative Design process By using Generative Design, engineers can create and simulate thousands of designs (many of which they may not have envisioned on their own) in a fraction of the time it would normally take. As additional benefit, the Generative Design process can yield highly […]

Workplace distancing solution to manage “next normal” manufacturing

Manufacturers are facing new challenges as they restart or maintain operations due to the Covid-19 pandemic. As preparations are made for the “next normal”, manufacturers must consider additional dimensions of employee safety, including the establishment of production environments and workflows that address physical distancing requirements. Combining proven hardware and software, Siemens has created a new solution that enables companies to quickly and efficiently model how employees interact with each other, the production line and plant design. The new solution also enables organisations to build an end-to-end digital twin, to simulate worker safety, iterate on and optimise workspace layouts and validate safety and efficiency measures to help future-proof production lines. With Siemens’ SIMATIC Real Time Locating Systems (RTLS), companies can continuously measure distances between workers, provide real time visual feedback to employees regarding their spacing from others and create a log of all movements and interactions over time. In this way the Siemens’ SIMATIC RTLS continuously facilitates safe distancing while providing numerous additional benefits. Combining SIMATIC RTLS with a digital twin of the actual manufacturing environment permits companies to model and simulate how employees interact with the equipment and each other, enabling them to iterate and optimise safety and productivity in the short term, and validate a redesign of the entire operation before more costly physical changes are made. In order to implement this solution, Siemens’ SIMATIC RTLS transponders are embedded in badges which are worn as personal protective equipment by all employees. RTLS receivers placed throughout the operation can then continuously track and record workforce movement. When two employees are in a risk scenario (e.g., less than six feet apart), their badges will display a warning, alerting them to the situation. The data collected over time can be analysed to identify “hot spots” where risk scenarios occur frequently. Such situations […]

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Advancing research: igus a new member of the Profibus Nutzerorganisation e.V.

Tested chainflex Profinet cables ensure reliable data transfer in moving applications Profinet is the world’s leading Ethernet-based communication solution for industrial automation. Because even large volumes of data can be transferred quickly and safely thanks to real-time communication. In order to advance the research of Profinet technology in moving applications, igus has now joined the Profibus Nutzerorganisation e.V. as a cable specialist. According to the results of a study by IHS Markit, Profinet is the industrial Ethernet communication system. Based on the newly installed nodes, Profinet achieved a market share of almost 30 per cent in 2018. The technology was developed by the Profibus Nutzerorganisation e.V. (abbreviation PNO). “Due to the increasing importance of Profinet in moving applications in industry, we have now joined the Profibus Nutzerorganisation e.V. as a cable specialist. Here we want to further advance the development of the technology”, says Andreas Muckes, Head of chainflex cables Product Management. “So the customer can be sure that our cable solutions always meet the current electrical requirements.” Profinet offers clear advantages for industry: a large amount of data can be transferred at up to 100 Mbit/s based on the Ethernet protocol. However, this also means that machines and cables must move increasingly more dynamically in a compact installation space: a challenge for standard cables. Therefore, igus has been developing cables that are specifically suitable for use in energy chains and on robots for over 25 years. For Profinet alone, igus offers nine types of cable for different application scenarios. Whether linear movement or torsion, the cable is guaranteed to last The chainflex Profinet cables are available in four jacket materials, four bend radii and two torsion angles. The igus product range offers solutions for small installation spaces, maximum speeds and three-dimensional movements with up to ±360 degrees/m on the […]

Energy chains vs. motor cable drums

The advantages and disadvantages of two industrial energy supply systems Whenever design engineers have to guide hoses and power and data cables in moving applications with long travels (more than 100 metres), the question arises of which energy supply system is the most efficient, especially considering such factors as reliability, maintainability, and future security? A motor cable drum? Or an energy chain? The advantages and disadvantages of the two systems are explored below. Candidate 1: The motor cable drum A proven energy supply that has been in use for decades – in applications such as cranes, transfer carriages, and the bulk material industry. The principle is simple. It is in its simplest form like a garden hose reel. When a gantry crane, for example, moves back and forth on its four supports, the cable is deposited on a prepared surface on the ground and is rolled back up on a drum mounted on one of the supports. There are several variants for retracting the cable. In addition to motorised drums, there are designs for shorter travels that work with spring force: the rolling action is normally either cylindrical or spiral rolling. In the cylindrical form, also called broad rolling, the cable first rolls up from left to right along the drum body. Then it rolls up vertically, layer by layer. Spiral rolling works differently. The cable is stacked immediately after the first rotation. The market for cable drums is growing. A key region is North America, and one reason is because the demand for cranes in the northern United States is rising. Another booming region is the Asia-Pacific, especially China and Japan. Among the reasons for this is urbanisation and a flourishing construction industry. According to Persistence Market Research, a market research institute, the global market volume will be more […]

Positives from Covid-19

-Dr Troy Coyle, HERA Director Our current state of play has created a massive disruption to business as usual – but are there any positives to come out from the Covid-19 pandemic? Covid-19 has dramatically impacted us all in many different ways. Of course, most discussions have been on the negatives of Covid-19, but here are five silver linings that we think may help build our resilience in the longer term. After all, it is those that take a negative and turn it into a positive that come out of situations for the better! So lets ensure that it is our NZ metals industry that is taking advantage! The significance of domestic manufacturing has come to the fore from Covid-19. We have had significant disruption to global supply chains. The expected market response is likely to be a shortening of supply chains and a strategy of securing supply chains. This undoubtedly favours local manufacturing. For a long time, manufacturing has not received the attention and support that it should have had – in terms of national security of supply chains and Government support. The PM’s specific mention of manufacturing in her announcement on 20 April indicates the sudden attention to manufacturing as a core requirement of Kiwi’s economic and human wellbeing. There is also likely to be a market change toward greater support for local manufacturing in consumer decision-making. Changes in consumer purchasing are also likely to support increased on-line purchasing. Both of these are, in turn, likely to lead to increased warehousing requirements and this will stimulate warehouse developments, with structural steel playing a role in via, for example, portal frame designs. There will necessarily be an increased focus on the upskilling of our workforce. Businesses were already struggling to attract and retain quality staff and many had gone offshore […]

OnRobot Soft Gripper highly flexible

The new OnRobot food-grade Soft Gripper is able to pick a wide array of irregular shapes and delicate items in food and beverage, cosmetics and pharmaceuticals production, as well as manufacturing or packaging Automation just got easier for food and beverage and other “clean” applications such as cosmetics and pharmaceuticals that need to handle items from eggs to fruit, to bottles or irregular-shaped containers. The flexible OnRobot Soft Gripper uses three interchangeable silicon-moulded cups in star and four-finger configurations to pick up almost any small object under 2.2kg with a delicate, precise touch. The electric Soft Gripper is food-grade certified (complies with FDA 21 CFR for non-fatty items and EC 1935/2004) and unlike traditional vacuum grippers, it requires no external air supply, so it can reduce both cost and complexity. “Our new Soft Gripper is challenging existing solutions for picking hard-to-grasp, delicate and odd-sized items,” says CEO of OnRobot, Enrico Krog Iversen. “Unlike proprietary solutions, the Soft Gripper offers seamless integration with most collaborative robots and light industrial robots through our One System Solution.” OnRobot’s award-winning One System Solution is a platform that provides a unified mechanical and electrical interface between leading robot arms and any OnRobot end-of-arm tooling (EoAT). The One System Solution has been newly expanded to include integration with robots from ABB Robotics and Hanwha Precision Machinery. Now, users of those robots can take advantage of the unified mechanical and electrical interface of any OnRobot product, for easier integration and faster ROI. While the Soft Gripper is ideal for food and beverage applications, it also provides flexible, delicate gripping for manufacturing and packaging. Soft Gripper Features: Up to 2.2kg payload based on shape, softness and friction of items to be handled Grip dimensions ranging from 10mm-118mm depending on cup used FDA certification Flexible, interchangeable silicon cups Ideal […]

Movac invests in Revolution Fibres to scale global growth

Auckland-based Revolution Fibres has raised $6m in a Series A funding round led by Movac, New Zealand’s most experienced technology investment firm. Founded in 2009 by Iain Hosie, Simon Feasey and Michael Perrett, Revolution Fibres has developed a unique technology to produce electro-spun nanofibres for use in a wide range of applications, such as filtration, skincare, sound absorption and composite reinforcement. Revolution Fibres has 15 employees and achieved early sales traction in several markets. Movac Partner David Beard comments “We have been targeting an IP-based business for Fund 4 for some time, and we were compelled to invest in Revolution Fibres because it had made a significant transition from R&D into scale volume manufacturing. With its applications spanning a diverse set of industries, it can adjust quickly and take advantage of a rapidly changing environment. We are delighted to have led this round which has included a diverse set of investors from NZ, US and Asia.” Revolution Fibres Chairman Andrew Turnbull comments “Iain and the team at Revolution Fibres have built a fantastic platform technology which is now ready, with the right team and funding, to be scaled. We’re very focussed on what we want to do with the business and sought an investor who understands what it takes to build a global deep tech business from New Zealand. Movac’s investment style and their experience in helping to grow value in companies with deep intellectual property meant a lot to us. Most importantly, there’s also a strong fit in terms of approach and aspiration.” The funding will be used to accelerate commercial opportunities in key offshore markets, and to invest further in production capability. Mr Beard will join the Revolution Fibres board. Phil McCaw, Movac Managing Partner commented, “We’re excited to have the opportunity to work with the Revolution Fibres […]

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