Developments

Exploring the virtual plant

How AR and VR can benefit manufacturing facilities When you think of Augmented Reality (AR) and Virtual Reality (VR) you might think of being immersed in a simulated world filled with mystical creatures like on PokemonGo. However, AR and VR are not just for our personal entertainment — these technologies are being used to benefit manufacturing facilities. John Young, APAC sales director of automation parts supplier, EU Automation, discusses the uses of AR and VR in manufacturing plants. A recent study across eight Asia-Pacific regions revealed that 95 per cent of people surveyed had used AR or VR technology. While this exposure is predominantly as a result of entertainment and social use, the study demonstrates people’s experience to the technology is widening, opening up opportunities into other sectors. One industry that could capitalise on the use of AR and VR is manufacturing, particularly for maintenance and training. Predicting maintenance with AR Augmented Reality displays virtual elements into an existing real-world environment, usually on a handheld device such as a tablet or mobile phone. Being able to view images, information or data overlaid onto the real-world scenario brings many possibilities for monitoring and maintenance in a manufacturing plant. If there is an issue, error or failure with a piece of machinery, AR could be used to view live information and data to help diagnose the problem. This early detection of faults means that issues can be fixed before a more serious breakdown occurs, helping to save costs by removing the need to replace entire pieces of the machinery. Early detection of a problem with equipment also allows maintenance managers to address the problem quickly. Having access to automation industrial parts suppliers means that maintenance managers can save time both sourcing the part and reducing downtime due to delivery delays. Virtual training […]

AI module to improve industrial production

Industrial workers can now more easily use the data from their equipment to predict production issues and improve processes with their existing automation and control skill set. The new FactoryTalk Analytics LogixAI module, formerly known as Project Sherlock, uses artificial intelligence (AI) to detect production anomalies and alert workers so they can investigate or intervene, as necessary. Many existing analytics technologies require deep expertise in both data science and industrial processes. But this add-on module for ControlLogix controllers reduces that burden by doing the job of a data scientist. It fits directly into a control chassis and streams controller data over the backplane to build predictive models. It can continuously monitor a production operation, detecting anomalies against its derived understanding. The FactoryTalk Analytics LogixAI module makes predictive analytics more accessible to help more workers make better production decisions. The module learns your ControlLogix application and tells operators and technicians when things are changing in unexpected ways. This can help them get ahead of product quality issues and protect process integrity. For example, the module can help operators spot performance deviations in equipment like mixers that could affect product quality or lead to downtime. It can also be used as a virtual sensor. Instead of workers taking a reading, like the humidity of a packaged food product, the module can analyse variables from line assets like sprayers, dryers and burners to predict a measurement, virtually. Factory Talk Analytics LogixAI has positive implications for businesses in any sector. By making available data that will assist workers in helping to ensure the smooth running of machinery, customers can empower employees to troubleshoot and solve problems as they arise, reducing downtime and ultimately contributing positively to the company’s bottom line. Workers can then be notified of problems by configuring alarms on a human machine […]

SSDT partners with Konecranes on China 2025 smart manufacturing targets

One of SSDT’s latest Konecranes 60/30 ton installations for precise and efficient die handling, with remote control for safety and clear vision. A company that has set its sights on achieving global leadership standards in automotive die manufacturing, Shanghai Superior Die Technology Co Ltd (SSDT), is partnering with Konecranes to help it achieve world-class standards of quality, reliability and safety required. The SSDT – an affiliate of SAIC Motor Corporation Ltd, employing more than 2300 people – has so far installed a total of 46 sets of Konecranes lifting technology as it expands its plants in Shanghai, Nanjing, Yantai and Wuhan. The lifting technology, composed primarily of Konecranes’ top-selling CXT types, is integral to SSDT die and automotive parts production and product handling as it builds towards its China 2025 industry development plan focussed on high-tech fields, including achieving top global standards of Industry 4.0 smart production strategies. SSDT produces hundreds of thousands of sets of doors, hoods, decklids, and front and rear floors annually, as well as manufacturing thousands of tons of large auto-body covering dies for domestic and overseas automakers. SSDT’s research and development drive since its establishment in 2003 has seen it produce new technologies, including ultra-high strength metal hot stamping dies and aluminium dies – something not previously produced in China and the quality and value of which is aimed at top end manufacturers in Europe. SSDT’s cranes – including its most recent repeat order for a set of double 60/30-ton types – are primarily equipped with high reliability Konecranes CXT hoists, of which more than 10,000 are sold every year. The CXT wire rope hoist is known for its efficient use of space under the crane and its excellent hook approaches. Safety is improved through high-performance brakes, durable wire ropes and remote operation. The […]

AI module to improve industrial production

Fully-fledged Smart Factory to be unveiled at SEMICON Southeast Asia 2019

KUALA LUMPUR Smart factories are becoming mainstream in the manufacturing industry, offering a new level of efficiency and productivity. Factories are no longer simply a mass of machinery operating as a series of siloed production lines. Instead, industry players are moving to managing interconnected networks of moving parts, something more akin to a living organism, that can be trained and fine-tuned to optimise performance. According to Ng Kai Fai, President of SEMI Southeast Asia, “In Southeast Asia, there is a rise in companies embracing smart manufacturing. Nations across the region are embarking on Industry 4.0 efforts on similar ground – by developing new policies, new tools to evaluate Industry 4.0 readiness and of course, introducing smart factories.” “Manufacturers are already leveraging on smart factory components in areas such as advanced planning and scheduling using real-time production and inventory data, and automation for workflow processes. But a true smart factory is a more holistic endeavour, moving beyond the shop floor toward influencing the enterprise and broader ecosystem. Smart factories transcend beyond the four walls of the factory towards a connected global network of similar production systems, and even to the digital supply network more broadly.” Given the complexity of Industry 4.0 integration into the E&E manufacturing ecosystem, SEMI Southeast Asia will for the first time showcase a fully-fledged smart factory at SEMICON SEA 2019, allowing delegates to walk through the entire end-to-end microelectronics supply chain. Each component along the smart factory multi-step line is displayed, virtually or with actual equipment on the floor, from design and materials through front-end patterning, packaging and test to final board and system assembly. There will also be subject matter experts in attendance as well as a unique AR interactive human-machine interface for delegates to experience. The smart factory will feature: – Journey Starts Here: GLOBALFOUNDRIES, […]

Innovative transition to new age of computing

Leading technology experts came together on the first day of the HKTDC International ICT Expo in April to discuss how advances in computing technologies have helped to make airports, businesses and governments smarter, more efficient and more cost-effective. The expo was organised by the Hong Kong Trade Development Council (HKTDC) and ran concurrently with the 16th HKTDC Hong Kong Electronics Fair (Spring Edition). Smart airport transforms passenger experience Hong Kong International Airport (HKIA) is taking biometrics and robotics to new levels in its digital transformation, aiming to provide passengers with a more efficient and enjoyable airport and travel experience, and to improve operational efficiency. Andy Bien, Chief Information Officer at Airport Authority Hong Kong (AA), explained the five key enabling technologies for realising the AA’s Smart Airport Vision: big-data intelligence, advanced biometrics, mobile technology, robotics, and the “digital twin” reality modelling system. Advanced biometric applications are helping the AA provide a seamless travel experience by combining all passenger airport interactions – self-bag drop, e-security gate, immigration, transfer security gates and self-boarding gates – into a single token. “When the system is complete, the passenger will be able to walk into the restricted area in about 10 seconds,” said Mr Bien. The AA is also developing long-range iris, palm-vein and finger-vein scanning, and deeper functions such as emotion recognition via smart CCTV for enhanced security, he said. The analysis of each detected face provides a confidence score for seven different kinds of emotions: anger, disgust, fear, sadness, happiness, surprise or neutral. Robotics is another area the AA is focusing on to supplement its huge labour force (currently 75,000 people and forecast to increase to 130,000 when the third runway opens). Mr Bien emphasised the fact that robotics integration was intended to supplement, not replace, airport workers. Driverless tractors will soon be […]

Hitachi to acquire robotic system integrator in the US

Hitachi will be entering the high-growth robotic SI(1) business in North America and accelerate the global development of its digital solution business, which connects the workplace and management, by acquiring a customer base, technology, and know-how in the Operational Technology (OT) domain. Hitachi has entered into a definitive contract for the acquisition of the robotic SI business mainly operated by an American headquartered company, JR Automation Technologies, LLC, from funds managed by Crestview Partners. Subject to the terms and conditions of the contract, Hitachi will acquire JR Automation, which builds production lines and logistics systems using industrial robots. As a result of this acquisition, Hitachi will enter the robotic SI business in North America, which is a region that is expected to see a high rate of growth. The acquisition is expected to be executed by the end of 2019, subject to the satisfaction of certain regulatory and other customary closing conditions. In the Industry Sector(3), Hitachi will continue to accelerate the global rollout of the robotic SI business, together with the acquisition of KEC Corporation (KEC), a Japanese robotic system integrator, for which an acquisition contract was completed by Hitachi Industrial Equipment Systems Co., Ltd. (HIES) in March 2019(4). In 2017, Hitachi acquired Sullair, an American manufacturer and seller of air compressors, marking a full-scale entry into the North American industrial product business(5). With the acquisition of JR Automation, Hitachi will acquire JR Automation?s customer base in the OT domain, along with advanced robotic SI technologies, know-how, and resources. Additionally, the acquisition of JR Automation will allow Hitachi to further expand its Lumada Solution business, globally. Lumada is Hitachi?s advanced digital solutions, services, and technologies business, which helps customers and management turn their workplace data into insights to drive digital innovation. In recent years, in the manufacturing and logistics […]

3D print of heart with human tissue

Scientists in Israel have unveiled a 3D print of a heart with human tissue and vessels, a first and a “major medical breakthrough” that advances possibilities for transplants. Scientists hope one day to be able to produce hearts suitable for transplant into humans as well as patches to regenerate defective hearts. The heart produced by researchers at Tel Aviv University is about the size of a rabbit’s. It marked “the first time anyone anywhere has successfully engineered and printed an entire heart replete with cells, blood vessels, ventricles and chambers. People have managed to 3D-print the structure of a heart in the past, but not with cells or with blood vessels. But the scientists said many challenges remain before fully working 3D printed hearts would be available for transplant into patients. Journalists were shown a 3D print of a heart about the size of a cherry, immersed in liquid, at Tel Aviv University as the researchers announced their findings, published in the peer-reviewed journal Advanced Science. Researchers must now teach the printed hearts “to behave” like real ones. The cells are currently able to contract, but do not yet have the ability to pump. Then they plan to transplant them into animal models, hopefully in about a year. Maybe, in 10 years, there will be organ printers in the finest hospitals around the world, and these procedures will be conducted routinely. However, hospitals would likely start with simpler organs than hearts.

Airlines can save money and the environment

More precise weather data means safer flights and smaller fuel consumption, as aircrafts can avoid unfavourable winds at given altitudes and start the descent phase at exactly the right moment. Swedish IT company AVTECH has developed a very precise weather and wind data product portfolio to help aircrafts fly as economically and comfortably as possible – without the airlines having to invest in any new equipment. In a recent real-life test, Norwegian Air Shuttle reduced CO2-emissions by 2 000 tons in three months’ time last autumn, by using AVTECH’s services in the company’s fleet of 106 Boeing 737-800 aircrafts. “We saved from one to eighty kilograms of fuel per flight, the average being 22 kilos, purely by optimizing the descent phase of the flights”, says Norwegian pilot and project manager Stig Patey. “The 10K weather grid makes it possible to avoid unfavourable winds at given altitudes during the flight and to start the descent phase at exactly the right moment. Our pilots have reportedly been very pleased with the easy to use service that in real life proved to be much more accurate than the standard weather systems.” All of this was made without any new equipment in the aircrafts, as all real-time calculations are made on the ground by AVTECH. “The timeliness and accuracy of our high-definition weather forecasting means that the normal pre-flight package is usually sufficient on shorter flights,” says David Rytter, Chief Technical Officer at AVTECH. “On longer flights updates can be uplinked when necessary, since the files are very small in size. Now the partnership with Norwegian has deepened, exploring the climb phase of the flight, with part of the funding coming from the Swedish Energy Agency.” World leading weather service AVTECH’s 10K weather is based on the UK Met Office’s high-definition weather modelling system, […]

Mitsubishi high-precision gear manufacturing systems for Chinese market

Mitsubishi Heavy Industries Machine Tool Co., Ltd. (MAT), a group company of Mitsubishi Heavy Industries, Ltd. (MHI) based in Japan, is ramping up its proposals of high-precision gear manufacturing systems for the Chinese market. As part of this initiative, MAT will be showing its integrated gear machining systems at “CIMT 2019: The 16th China International Machine Tool Show” being held in Beijing from April 15 through 20. The focus of MAT’s exhibit will be the “ZE26C,” a gear grinding machine capable of suppressing final gear-tooth shape error to 1μm. The ZE26C will respond to needs for higher speed and precision especially in the transmission systems of electric vehicles and the reduction gears used in robots. This will be the first time MAT is exhibiting the ZE26C at an industry event of this kind. The ZE26C was developed to finish hardened and tempered gears with outer diameters up to 260 mm. Superior performance has been achieved by making vast improvements to the “ZE-B,” MAT’s earlier series of widely acclaimed gear grinding machines. Specifically, the ZE26C’s grinding precision and stability have been enhanced by increasing the rigidity of the column, table and grinding wheel head, coupled with revamping of the spindle structure. In addition, by increasing cutting speed and reducing idle (non-cutting) time by roughly 50% compared to earlier models, the ZE26C boosts high-volume production capability and promotes lower running costs. Furthermore, by expanding the maximum wheel width to 160 mm (from 125 mm on previous models), frequency of wheel replacement is reduced and simultaneous mounting of standard and polishing grinding wheels becomes possible, resulting in higher cutting precision. Also, adoption of the industry’s first water-soluble coolant (optional) improves environmental performance while also enhancing energy savings. At CIMT 2019 MAT will also be demonstrating its “GE25A” dry-cut (i.e. requiring no cutting oil) […]

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