Engineering

3D Design & Simulation Tools Ushering in a New Dawn for Asian Manufacturing

Ming Xu – CAE Marketing Manager,Asia Pacific Marketing,Siemens PLM Software. Asian manufacturers are on the cusp of the next industrial revolution with innovation as the catalyst that is redefining their path to success. With great opportunities come great challenges – the current Asia Pacific manufacturing scenario is seeing multiple impactful factors at play. The pressure to shorten time-to-market, design highly customisable and energy-efficient products is driving companies to rethink their manufacturing strategies. To add to this, we live in a culture of instant gratification and immediate results. Continuous and consistent improvement is the only way to stay ahead of the competition. To win in this highly complex marketplace, we need to identify trends with the potential of optimizing product development processes in order to maximize our advantage. Integrated 3D Design and Simulation for Reimagining Processes A great product is born well before the raw material reaches the machine. High quality products start their journey from high quality designs. Virtual prototyping (the process of creating an optimal physical design in software before building a physical prototype for verification) is experiencing a widespread usage in today’s manufacturing processes. It has assumed a much greater significance in recent years as engineering design has evolved drastically thanks to the availability of cutting edge design tools and software. Today’s leading manufacturers’ use advanced 3D design (CAD) and simulation (CAE) software in their research and development (R&D) processes to pre-empt, assess and avoid errors. Simulation guides critical trade-off decisions to balance competing product objectives such as reliability, cost and weight requirements. It also plays a major role in product and process innovation. Both CIMData and Scientific Computing World have noted how pivotal CAD/CAE integration is to product development. Historically, simulation has often been out of step with the design schedule with results too late to be […]

Herculon tank top bearings meet climate change and production challenges to liquid protection

Storage tanks today can hold upwards of 10, 20 or even 30,000 tons of liquid that must be protected from the elements and from pollution to safeguard it for use in water, waste water, emergency fire protection and high purity industrial processing applications. Not only are tanks being built to hold their contents more safely and securely than ever before, but they are expected to do it for longer and in more challenging operating environments where steel, concrete and fibreglass tanks need secure roofs that can withstand expansion and contraction caused by factors such as increasing climatic and load variations. A challenge facing developers and operators of buildings and processing plants for industrial and municipal uses is ensuring their top structures can flexibly cope with internal movement from climatically induced expansion, contraction and wind and rain forces, while also coping with production stresses caused by heavy and changing loads, vibration and other factors encountered within diverse industries. Relevant industries can include mining and energy, oil and gas, ports and infrastructure, food and beverage, primary processing, manufacturing, materials handling, water and waste water utility and emergency services. A cost-efficient solution to many such issues is offered by Hercules Engineering through its range of Herculon Type D Tank Top Bearings (HLD/TT) Bearings, which are custom-designed for easy installation under roof beams of tank tops and other lighter structures including some building roofs. These low-friction easy-slip bearings are particularly useful where loads are relatively small but both lateral and uplift forces need to be accommodated, says Mr David Booty, Manager, Hercules Engineering (a division of Cut to Size Plastics). “Light but strong and flexible tank tops are now widely employed to protect tanks and their contents from external pollution ranging from flora, fauna, dust and droppings and water-borne impurity. The bearings used under […]

AutoMATE 7-Axis robotic machining cell – On show at SouthMACH 2015

The largest Nachi robot ever sold in New Zealand was on show at SouthMACH in July – in the form of a 7-axis robotic machining centre from NZ based robotic machinery builder AutoMATE™. Design Energy Limited, owners of the AutoMATE™ brand and NZ distributor for Nachi Robotics, have developed a robot machining centre based on the newly released Nachi SRA210 six axis robot. This particular system, for customer Cutting Innovations in Auckland, is equipped with a 7.5kW – 24,000rpm HSK tool-change spindle, rotary table and PowerMILL CAM software. The result is a system offering a machining envelope of 2.5m x 2.5m x 2.5m with +/-0.25mm accuracy. Mike Shatford, Director of Design Energy explains: “AutoMATE™ machining centres are highly adaptable, with robot and fixturing options available to suit a wide variety of machining requirements. The high level engineering used to develop each system structural loading of each machine is carefully analysed using FEA analysis. Providing high levels of rigidity and stiffness are key to successfully carrying out machining operations using a multi-axis robot.” The team at Design Energy are already considering producing further machining cells of various configurations and would be keen to hear from interested parties. Contact:info@designenergy.co.nz

Fluke 3000 FC Series Wireless DC Clamps improve productivity

New high current and 4-20 mA dc current clamps speed troubleshooting through collaboration, regardless of location Now added are two new dc current clamps to the Fluke Connect system of wireless test tools: the Fluke a3003 FC Wireless DC Current Clamp and the a3004 FC Wireless DC 4-20 mA Current Clamp. Both fully-functional current clamps can wirelessly send measurements to Fluke Connect enabled master units as well as the Fluke Connect mobile app so users can view measurements from multiple devices simultaneously, review equipment history, and share measurements with other team members for faster troubleshooting. The a3003 FC Wireless DC Current Clamp measures up to 2000 A dc making it ideal for very high dc current measurements typically found in utility and dc machine controller applications. It features a large jaw size (64 mm) for clamping around and measuring on large, high current conductors. The a3004 FC Wireless DC 4-20mA Current Clamp measures 4 to 20 mA signals without breaking the loop so process control technicians can make accurate measurements without interrupting the workflow. It features a detachable clamp with extension cable for measurements in tight locations. Both current clamps can record and store up to 65,000 measurements with the logging feature to isolate intermittent events or record fluctuations without even being there.

Maintenance supervisors can boost productivity?

The job of maintenance supervisors is to get the maintenance work completed on time, on budget and safely! They can be popular. They can be great communicators. They can be inspired trainers. They can be great repair people. But these things alone do not make successful maintenance supervisors. They are not successful maintenance supervisors unless they can keep the machines running, the fleet rolling and the occupants warm in the winter. When does an active supervisor look like when he is no longer bogged down in an office doing paperwork? Active supervision occurs when a supervisor spends substantial time on the shop floor helping workers solve problems. As strange as it might sound, on the psychological level a supervisor might have to be both mother (nurturing and supportive) and father (strict and tough) to members of the crew. Active supervision encompasses several roles: • Ongoing performance monitor: The supervisor knows how long each job should take and checks it periodically throughout the day. A four-hour job issued in the morning should be done by the lunch break. When the jobs fall behind, the experienced supervisor thinks about how best to intervene. In some cases it might be logistical help, helping with equipment, or providing guidance about how to proceed. • Paperwork compliance officer: The accuracy of all analysis is derived from the work order. If the work order is complete and accurate then decision-making and root cause analysis become dramatically easier. Supervisors audit paperwork and return it when it is deficient. They should always look at work orders on the floor and ensure entries are being made at the same time as the activity occurs, not at a later time. • Obsessive-compulsive PM monitor: A supervisor reinforces the rule: “Do the PM as it is written.” A related issue is […]

Electroplating Engineers of Japan Launches Ultra-compact Plating Laboratory Equipment

TOKYO, July 15, 2015 – Tanaka Holdings Co., Ltd. today announced that Electroplating Engineers of Japan, Limited (EEJA), which operates the Tanaka Precious Metals’ plating business, has developed, and launched from July 15, the RAD-Plater cup-type[1] ultra-compact plating laboratory equipment for semiconductor wafers, which achieves equivalent films to mass-production machines. The RAD-Plater is ultra-compact laboratory equipment for manufacturing 2 to 8 inch semiconductor wafers. Measuring 800 mm wide and 700 mm deep, it is smaller than mass production machines and can operate on only compressed air and the 100 volt power of general equipment. In addition to gold, silver, palladium, copper and nickel, it can use a wide variety of plating solutions including alloys and lead-free solutions, and at 10 liters or less of solution, it uses about half the plating solution required by dip-type machines, which also reduces experimentation costs. The RAD-Plater uses an EEJA-manufactured Stir Cup[2] and delivers mass-production level plating quality through uniform and bubble-less film thickness and superior filling of deep vias[3]. It also enables reduced plating time by using a high current density[4] achieved with an increased ion supply. Even though the RAD-Plater is laboratory equipment, it achieves a level of plating equivalent to that of mass-production machines, which enables early problem-solving in the development stage for mass production issues such as expected yield, and enables trouble-free rollout to the mass-production line. This is the world’s first cup-type plating laboratory equipment for manufacturing semiconductor wafers, using 10 liters or less of plating solution and handling 8-inch wafers. Many development divisions of manufacturers with mass-production plating lines would have previously contracted out the plating solution experimentation work to equipment manufacturers and others for evaluation, but purchasing a RAD-Plater and conducting experiments in-house now enables a considerable reduction in development lead times. Other customers would have previously […]

Strong International Presence at MTA VIETNAM2015 Set to Boost Vietnam’s Manufacturing Scene

Ho Chi Minh City, Vietnam, July 7, 2015 – Since August 2013, Vietnam’s benchmark purchasing managers’ index (PMI) for manufacturing has expanded every month. With its attractive location in Indochina, young population and low costs, the country has also drawn investment from renowned international brands such as Intel, LG Electronics, Samsung Electronics and Siemens[1]. This bodes well for foreign companies and investors keen to expand their business presence in Vietnam and the region, as well as for Vietnamese companies looking to extend their business networks internationally. MTA VIETNAM2015 – Strong support from international groups set to boost local manufacturing sector Launched in 2005, MTA VIETNAM2015 is to date the only manufacturing event in the country that attracts the most number of international group pavilions. This year, 346 exhibitors from 20 countries and regions, including 10 international group pavilions from Germany, Japan, Korea, Singapore and Taiwan are present. Featuring an increase of about nine per cent in exhibition space occupied from the previous year, this 13th edition of MTA VIETNAM has sold out its exhibition space many months before its opening. Spotlight on Japanese technology A stalwart group participant, the Japan External Trade Organisation (JETRO) is once again back at MTA VIETNAM, this time with a contingent comprising 22 companies that specialise in metalcutting, metalforming, metrology, cutting tools and tooling systems. Group exhibitors such as Aizaki, Asada, Enomoto, Kira, Konno, Mishima, PMT, Segawa, Towa and Rex are showcasing machines and solutions that have been specially handpicked for the local Vietnam market, to increase manufacturing productivity and quality levels. Mr. Yasuzumi Hirotaka, Managing Director from the Ho Chi Minh Office of JETRO said, “Vietnam’s manufacturing industry is in the growth cycle and shows promise of further expansion. We see opportunities for collaboration between Japanese and Vietnamese companies in the sector and will […]

Internet of Things Top Trends

Old products will be re-invented and whole new ventures will emerge overnight to focus on the analysis part, and define service on top of it. Software AG has released its picks for the top trends for the Internet of Things (IoT). The overarching theme highlights the need for better regulation and security for widespread adoption. The Internet of Things is a revolution. There will be serious threats to those who are not prepared and profitable opportunities for those who are. Issues such as security and governance will need to be addressed as IoT begins to impact more and more of our daily lives. Software AG’s Top Internet of Things (IoT) Trends: 1. Don’t Gamble with IoT: Untrustworthy Things will be treated like gamblers in a casino – under close surveillance and approved until they misbehave. Traditional methods of on-boarding Things using explicit authorisation will be insufficient as IoT proliferates. 2. Intelligence on Things gets up close and personal: As intelligence on the Internet of Things becomes critical to decision-making, it will become necessary for analytics to reside close to the Things being analysed. Analytics will evolve both in the cloud and on the “outer edge”— either on the Thing itself or on a gateway nearby. 3. Say hello to your virtual assistant: IoT will enable consumers to adopt a “virtual assistant,” which will act in a semi-autonomous manner in the home — monitoring sensor-enabled Things to replenish light bulbs, order prescription medicines or buy groceries online. But consumers will demand assurances of security and privacy before embracing the trend. 4. Pay-as-you-go Things: The Internet of Things will accelerate the pay-as-you-go model for products. All products will be sold with something “smart” embedded within them. For example, a washing machine could be offered cheaply, or even for free, with the consumer […]

Adapting to the new frontiers in the manufacturing industry

Increasing operational effectiveness generally translates to process improvement initiatives. Best steps towards an efficient project community through recognition of the most definitive drivers at a time when PM and project portfolio management is gaining prominence Over the past decade, the manufacturing sector has witnessed a complete transformation across the globe. With large developing economies effectively handling competition against mature markets and transforming into first-tier manufacturing powerhouses, the changes have been unprecedented. Manufacturers have also experienced spontaneous growth in unstable markets around the world and skilled talent has remained in short and unbalanced supply in different regions. The entire evolutionary process has seen manufacturing organisations focus on demonstrating business value, with project governance and metrics playing an increasingly important role in keeping management informed about project performance and its impact on the bottom line. In an industry as diverse as manufacturing, project management as a management discipline has emerged as an important channel in highlighting much economic activity. Increasing Strategic Role of Project Management Manufacturers in recent years have discovered that project management’s reliable methodologies fit together ably with the overall processes and in every area of production. As business leaders continue to adapt to the increasing market volatility, project management is playing a big step closer to business strategy. A fully aligned programme and project portfolio management strategy includes the entire organisation, mandating project execution at every level and aiming to deliver value at each step. Best Steps to an Efficient Project Community Recognising the most definitive drivers that critically impact the skills requirements and competencies development of the project community in the manufacturing industry is essential. Identifying these four drivers and implementing the right measures respectively is paramount to achieving project success. Given the dynamics of the manufacturing industry, the pressure to produce, to gain or retain competitive advantage […]

Rockwell Automation simplifies model predictive control with Pavilion8 software

Rockwell Automation Pavilion8 Model Predictive Control (MPC) software now delivers a more user-friendly configuration environment, step-by-step prompts, warning diagnostics and flexible work flows to simplify building, maintaining and adjusting highly complex process models. Pavilion8 software has long been known as being among the most powerful software for solving highly challenging control problems, and it is now also among the easiest to use. The solution builder tools within the software now offer MPC configuration in a modern Windows environment, giving users a more familiar and streamlined experience. For example, users can now execute right-click mouse operations and complete copy-and-paste-type actions to develop applications in the software, helping them deploy their solutions faster and reduce training and adoption times. Pavilion8 MPC v5.0 software remains control system independent, but smoothly integrates with the PlantPAx process automation system from Rockwell Automation and includes four key enhancements. Windows-based configuration and support – An improved overall user experience for expert and inexperienced users alike begins with the updated, Windows-based solution builder tools, which improve work flow by enabling users to create a customized working environment and providing access to online help. For example, problems that arise during configuration will now prompt helpful, context-sensitive warning and error messages. Users can simply click on these messages to receive detailed model-creation steps that will guide them toward a resolution. Users can also more easily modify past work to simplify model maintenance and re-use. Multivariable run-time controller – Users will also discover new time-saving features in version 5.0. The robust run-time controller has been updated to allow users to add new predictive disturbance measures in half the time as the previous version, and easily compare differences in MPC application versions. Users now can easily sort, re-name, add, delete, compare and copy MPC variables and software supporting a flexible work flow, […]

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