Smart Manufacturing

Electric car lithium battery pack and power connections. Blue toned.

Mazda drives creativity using generative engineering tools

Mazda Motor Corporation has adopted the Capital electrical design software suite from Mentor, a Siemens business, to help maximise innovation in the design of next-generation automotive electrical systems. Recognised worldwide for its successful launch of innumerable innovative technologies, Mazda uses Capital for model-based generative design for the electrical and electronic systems of the entire vehicle platform. The Capital automated generative design flow helps Mazda automotive design teams manage design complexity and changes across the entire vehicle platform, minimising errors and reducing costs. The development of safe and efficient electrical designs has become a critical task as the automotive industry moves towards large scale system developments such as electrified powertrains and autonomous driving. These designs are often based on entirely new architectures and have become so complex that advanced software tools are needed to enable development efforts. Capital tools deliver real time feedback against target metrics such as cost, weight, and network bandwidth consumption. This allows engineers to explore alternative design approaches, which is extremely important for large scale system developments represented by electric and autonomous vehicles. Capital software also provides Mazda with extensive simulation and verification functionalities. At Mazda, from system design, harness design and verification down to manufacturing and service documentation, outputs of each process have been generated in its natural language, requiring designers to translate between processes and fill in the missing pieces using their talents and skills. “In order to remove ambiguity while maintaining the diversity of expressions that are characteristics of these natural languages, we applied formal methods to eliminate the loss in information transfer and set a goal to build a development environment that is consistent and connected all the way through the manufacturing phase,” said Kazuichi Fujisaka, Technical Leader, Mazda Motor Corporation. “Furthermore, we also aim to shift to a development methodology that allows […]

Bringing automation barriers down with end-of-arm tooling

Historically, one of the biggest barriers to automation has been cost and time constraints associated with the production setup. The procedure is usually performed by a team of robotics experts adept in programming languages and advanced engineering, subjects unfamiliar to most. Demand for automation is flourishing from various manufacturing sectors leading to greater innovations in industrial robotics. With this trend, companies are prompted to adapt more and more intelligent tools that can help the production workforce with faster deployment and installation, saving their precious time on planning and strategy. But not many businesses have been able to do so quickly because most are not ready to address collaborative applications with newer technologies. This is due to limited knowledge or resistance to adopting modern end-of-arm tooling (EOAT) with collaborative robots (cobots). Continuous technology transformation and the rise of collaborative applications in industrial automation have made robots easily deployable. Intelligent EOAT devices come with in-built features that can be programmed easily, enabling faster set-up. With EOAT, automation becomes more inclusive, delivering collaborative applications to meet modern automation needs. Automation Adoption Rises in ASEAN The ASEAN region’s combined GDP hit almost USD2.7 trillion in 2017, four times the value in 2000, clocking an average 5.3 percent yearly growth. ASEAN could become the world’s fourth largest economy by 2030 if this growth maintains.[1] To achieve this, the region needs to leverage the opportunities presented by Industry 4.0 technologies. Adoption of these technologies remains slow in most countries however, with many manufacturers still relying on outdated processes[2]. Singapore is spearheading the adoption of automation and robotics, recording the second highest industrial robot density globally at 658 robots per 10,000 employees.[3] Malaysia and Thailand have also increased their focus on automation, encouraging greater use of robotics through the National Policy on Industry 4.0 (Industry4WRD) and the […]

The four factors essential to building a quality production line

-Andrew Stackpole, Assembly Shop Manager at Facteon Developing an efficient and polished machine building process can take a manufacturing company decades. What’s most important is that throughout this process, the focus is on building a quality production line that allows for the manufacturing of best-in-class product. Since beginning my career as a Machine Builder in 1994 and working through to my current role as Assembly Shop Manager at Facteon, I’ve come to learn that there are four key factors involved in developing a quality production line. 1. Quality components produce quality product By keeping the production of machinery components in-house where practical and possible, you will play a more active role in quality control. It was for this very reason that Facteon established its own in-house Build Shop and Machine Shop to cater to internal and external customers. The team retains full control over every component produced and as it’s not heavily relying on delivery by third parties, it can be certain that the component will be available on site when required. To achieve the necessary levels of precision in component manufacturing, collaboration is key – both in the initial phase of producing your components and in the build phase of the production line. Looking at opportunities to integrate the latest technologies with more traditional machining methods, will allow you to fully harness the potential of the machinery while using the latest technology to improve precision and efficiencies. Partnering with reliable external suppliers For any components that can’t be produced in-house, consider looking beyond your own capabilities and using the services of thoroughly vetted external providers. For example, Facteon uses suppliers based in New Zealand, China and the United States and vets these suppliers through a tiered rating system to ensure that our standards are met. If you’ve outsourced the […]

Housing construction is becoming manufacturing

Manufacturing is usually associated with making parts and assembling them. Manufacturing complete houses is a relative new concept in the history of the industrial revolution. We are on the verge of the next step, making the complete structure for a house out of only one material, foam concrete. Recent developments have made it possible to make foam concrete to high specifications, good thermal and acoustic insulating properties and reasonable strength compared to “normal” concrete. We are talking here about foam concrete that is half the weight and has more than five times the thermal insulation factor. On top of that it is more flexible, so it can withstand earthquakes better. If you are in a war zone it can protect you from flying objects, as it has a high energy absorption rate. All this creates a comfortable, healthy and safe home for a reasonable cost. So why is everyone not using it? Mainly because the mortar mixes do have a few more ingredients in it, and the ratios of the components are critical, in addition you need a foam making machine to make the foam, and then mix it in with the mortar. All of this together puts people off using it as it is more complex than making “normal” mortar. In a factory environment it is easier to control the production process, including the curing. As with all concretes the “drying” time and conditions have an influence on the end result, the final strength and flexibility. On-site it can be difficult and costly to maintain the ideal conditions, keeping it wet and at the ideal temperature. Manufacturing foam concrete products in a special designed facility has many benefits, good control over the delivery and storage of the raw materials, use and maintenance of the equipment, labour input, less skilled […]

Boeing 787 Unified Livery In-flight over Clouds

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 visualisation 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 […]

Your future co-workers could be a swarm of robots

In the future, swarms of robots could help us perform tasks from search and rescue to farming. Imagine there’s a flock of aerial robots searching for a lost hiker, for example. They have to cover a large area of remote bush and a central commander won’t work because they’re so spread out. So, instead, the robots work cooperatively to calculate the best way to cover and search this large area accurately and speedily. This scenario is less Black Mirror than it sounds, and more about focusing on practical solutions for jobs that are difficult for humans to do, says Airlie Chapman from the Melbourne School of Engineering. Describing the focus of her research in mechatronic engineering, Chapman says “it centres on multi-vehicle robotics, or many robots working together to achieve a common goal”. Mechatronic engineers explore developments in automation and manufacturing—blending multiple disciplines of engineering. And it can involve creating smart machines that are aware of their surroundings and can make autonomous decisions. Chapman works specifically in the field of multi-vehicle, or swarm, robotics. Using a combination of mechanical, electrical, and software engineering to build the robots, Chapman then programs the vehicles using algorithms to react and think autonomously. Many bots are better than one “There are benefits to using many smaller unmanned aerial vehicles (UAVs) in place of one large one, particularly for jobs like cleaning up an oil spill, environmental monitoring, or searching for survivors of a mine collapse,” says Chapman. Not only is there the element of redundancy with smaller vehicles—losing one small UAV out of a group is less of a problem than losing a single large UAV—but there are also the implementation benefits. For one thing, there’s the improved coverage capability and reduced cost. “A swarm of cheap small robots, each with little capability, can […]

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 […]

Australian Defence looks to quantum mechanics for new technologies

Researchers from the University of Adelaide in South Australia will develop three technologies after being named among 11 projects to share in A$6.6 million of funding from Australia’s Department of Defence. The projects include the development of underwater devices to detect submarines, research into whether quantum radars can be used to detect stealth aircraft and the development of an ultra accurate portable clock to improve GPS satellite technology. The funding consolidates the University of Adelaide’s Institute for Photonics and Advanced Sensing (IPAS) as one of Australia’s leading centres for the development of quantum sensing and photonic technologies. IPAS director Professor Andre Luiten said the funding also reaffirmed Defence’s interest in developing quantum mechanic capabilities in South Australia. “Everyone believes that there’s going to be a revolution over the next 20 years where quantum technologies end up in everything,” he said. “The initial objective is to provide those technologies to defence but it’s also about training up Australian students so they have an understanding of quantum technologies. “Australia needs to build up its sovereign capability in this area and train students.” The Next Generation Technologies Fund aims to develop Australia’s quantum mechanic opportunities, which focus on the study of the motion and interaction between subatomic particles. One of the IPAS projects will utilise magnetometers in underwater geophysical discovery contexts to track submarine activity. Professor Andre Luiten said the technology, primarily employed to detect variations caused by the presence of ferrous (unoxidized) iron in the total magnetic field, will be applied for Defence to discover underwater vessels. “These magnetometers can detect very small magnetic fields,” he said. “The goal of this project is to build sensors that go on the seabed which detect the presence of submarines through their properties. “You’d essentially set up a trip wire around assets that are of importance to Australia.” The […]

NUM helps Taiwanese machine tool company automate production for robotics

* unique multi profile capability helps increase manufacturing productivity NUM is helping the Taiwanese machine tool company Chien Wei Precise Technology to develop innovative CNC grinding machines for manufacturing specialist gears used in robotics applications. Based entirely on NUM’s latest-generation Flexium+ 68 CNC platform, Chien Wei’s new machines are designed to speed the production of both involute and cycloidal profile precision gears. They are believed to be the first gear grinding machines on the market that are capable of handling both types of gear profile. There are two versions of the grinding machine, one for internal gears, the other for external gears. Founded in 1981, Chien Wei Precise Technology Co., Ltd is based in Fengshan District in southern Kaohsiung, Taiwan. The company initially specialised in precision machine tools such as vertical grinders, jig grinders and machining centres, together with co-ordinate measuring machines (CMMs). Over time, it also diversified into robotic automation systems. Robotic systems typically use either planetary gearboxes equipped with involute gears, or cycloid drives based on a combination of a reduced epitrochoid rotor and a cycloid stator. While planetary gearboxes have been around for a long time and enjoy extensive use, cycloid drives have far fewer moving parts and offer a more efficient means of achieving extremely high reduction rates. A speed reducer with a ratio of 200:1 would typically need a chain of three planetary gear boxes with twelve moving involute gears. The same reduction ratio could be achieved with a cycloid drive using one stator and one rotor. However, cycloid gears are notoriously difficult and expensive to manufacture. In 2015, Chien Wei decided to bring gear manufacturing in-house, by developing its own gear grinding machine. By producing its own gearboxes the company could control quality, shorten lead times and reduce costs. It would also enable it […]

Universal Robots Eyes Industry4WRD Potential

Robotic automation key to transforming Malaysia’s manufacturing sector Industry4WRD: Promote higher adoption of Industry 4.0 related technologies Low industrial robot adoption: 45 units per 10,000 employees in 2017 Cobot benefits: productivity, quality and workers’ well-being Universal Robots (“UR”), Denmark-based collaborative robots (cobots) market leader has identified Malaysia as a key growth market in line with the country’s increased focus on automation and robotics, as outlined in its National Policy on Industry 4.0 (Industry4WRD), to transform its manufacturing sector. The manufacturing sector, comprising 98.5 percent of Malaysian SMEs[1], serves as a major contributor to the country’s economy. In 2018, the sector contributed 22.4 percent of GDP, roughly RM 325 billion[2]. Sakari Kuikka, General Manager, Southeast Asia and Oceania at UR said: “Malaysia deployed just 45 units of industrial robots per 10,000 employees in 2017, almost 50 percent below the global average of 85 units.[3] In a 2017 FMM-MIER survey, only 7.4 percent of Malaysian respondents used autonomous robots – 23.3 percent of which were SMEs.[4] We see huge potential to boost the adoption of robotic automation as the country focuses on strengthening its manufacturing sector and gearing towards becoming a developed nation,” he added. Since its entry into the Malaysian market in 2013, UR has actively expanded its distribution base. Its cobots are distributed by Bizit Systems, EPCO Precision, Multitrade Asiapac, Servo Dynamics, T.E.M. Engineering and TMS Collaboration Automation. “Malaysia ranks high in the region in terms of Industry 4.0 readiness according to global surveys[5]. However, this is not the sentiment shared by SMEs who are slow to adopt these technologies. Among the challenges they face included lack of understanding of automation benefits and low awareness on government funding to assist with tech adoption. Last year, about RM5bil was set aside by the government to help businesses embrace smart technology including automation […]

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