Smart Manufacturing

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) […]

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 […]

The critical role of IIoT in the future of food processing

Michael Cahill, Rockwell MES Technical Consultant As the old adage goes, an ounce of prevention is worth a pound of cure. New Zealand food companies, that often produce high value-add product that is exported around the globe, value their brand and reputation. Things are changing. Customer expectations for food safety and quality are unprecedented. Expectations from regulatory authorities are increasing to meet ever growing market regulation. Demand for high safe products is driving growth at an unprecedented rate. The reality is the number of food recalls has been steadily increasing over the last decade, according to FSANZ’s 2009-2018 reporting. The lack of visibility in the early stages of production is leading to an increased amount of inedible product and is posing serious food safety compliance risks. With headline after headline, product traceability from paddock to plate is becoming more and more important. Any deviation in quality in the product line will involve significant wastage and financial burden on the organisation. A sustainable approach to maintain the highest standard of production quality is sought to meet these customer, regulator and growth challenges. Connecting the dots The rise of the Industrial Internet of Things (IIoT) has emerged as a solution to this problem. IIoT platforms and advanced analytics now enable users to fuse multiple data sources to provide contextually relevant historical and real-time data. Add in AI and machine learning and food manufacturing is more predictive and intelligent than ever before, giving workers uncanny insight into how to solve issues and predict problems before they happen. The problem isn’t a lack of data but a lack of connectivity from food companies. IIoT has provided the tools to better verify quality, establish batch genealogy and capture meaningful processing data from beginning to end. It’s now the job of manufacturing plants and farms to […]

iSolutions-Range-To-Meet-Taiwan’s-Smart-And-Sustainable-Manufacturing-Needs Asia MN

iSolutions range to meet Taiwan’s manufacturing needs

Leveraging intelligent manufacturing as the key to Taiwan’s economic revitalisation, leading pump manufacturer Grundfos introduced iSolutions – a product range with a focus on digitalisation and connectivity – at this year’s Taipei International Machine Tool Show (TIMTOS). In line with the government’s ambition to transform Taiwan into a global manufacturing hub by pushing industry adoption of smart machinery, Grundfos showcased a number of machine tool products under its iSolutions range. These products are intuitive and connected solutions that feature intelligent monitoring and adjustment features, which in turn optimise performance of the entire water system. A key product of the iSolutions range is Grundfos’ E-motor, which comes with a built-in frequency converter and sensors that enable the motor to intuitively control pressure from the pump to match the system’s demand, ensuring optimum levels of operation at all times. This drives significant financial and energy efficiencies, in contrast to conventional systems that tend to run at constant speed and pressure throughout their operations, regardless of fluctuating demands. With strengthening competitiveness and sustainability being key to the local machining industry’s projected growth of 8 per cent each year[1], Eric Lai, Grundfos’ Global Business Director, Machining Industry, said, “Grundfos is committed to helping Taiwan achieve its goals for intelligent machinery to enable manufacturers to offer more value-added services at greater productivity and environmentally friendly levels. As a leading pump solutions provider, we seek continuous development and innovation to ensure that each new pump is meeting the evolving needs and challenges of industries locally and regionally. “With pumps accounting for 10 per cent of the world’s electricity consumption, the opportunity to leverage Industry 4.0 to integrate intelligence into pump manufacturing and reduce both financial and environmental costs is unprecedented,” Eric Lai added. According to Grundfos, the potential of intelligent pumps in the iSolutions range can […]

OMAX to join forces with Hypertherm

OMAX Corporation, a manufacturer of abrasive waterjet systems, plans to join forces with Hypertherm, a U.S. based manufacturer of industrial cutting systems and software, following the signing of a definitive merger agreement that establishes OMAX as a wholly-owned subsidiary of Hypertherm. Upon the closing of the transaction, expected on or around April 9, OMAX’s industry leading direct drive pumps, software, and applications technologies will combine with Hypertherm’s complementary portfolio of intensifier-based pumps and abrasive recycling systems, to form the industry’s leading waterjet technology offering. “When the late Dr. Olsen and I founded OMAX 25 years ago, our goal was to combine new motion control technology with software to create an abrasive waterjet system unlike anything else on the market. We more than succeeded, creating one of the world’s top waterjet manufacturers,” said John Cheung, co-founder and CEO of OMAX. “Together, we have been planning for the future of OMAX for some time. In planning for this future, we wanted to partner with a company that shared our values and vision. We wanted a company that would protect our culture, provide stability for our employees, and give our customers products and services consistent with our mission statement. Though Dr. Olsen is sadly not here for today’s announcement, I am comforted knowing he completely supported and wanted this for OMAX.” “Hypertherm is excited to welcome OMAX to our family and to bring together the leading waterjet R&D and engineering team in the world with our hardworking and talented waterjet team in Minnesota,” said Hypertherm president and CEO Evan Smith. “We are confident the combination of OMAX’s cutting-edge technology and solutions, innovation focus, strong brand name, commitment to customers, and excellent culture is a perfect complement to Hypertherm’s waterjet offerings and plasma cutting industry leadership position. It enhances our strategy of delivering cutting […]

Siemens acquires noise, vibration and harshness business from Saab Medav

Siemens announced today that it has signed an agreement to acquire the Noise, Vibration, and Harshness (NVH) end-of-line quality testing business of Saab Medav Technologies GmbH, a global provider of state of the art signal processing, communications intelligence and analysis for air, land and naval applications, as well as NVH solutions for industrial quality testing. The unique NVH quality testing solutions offered by Saab Medav have a strong track record and have established innovative best practices in the domain of end-of-line quality testing of combustion engines, transmissions, electric motors and motor driven components and systems. The addition of Saab Medav NVH allows Siemens to complement its Simcenter™ portfolio of testing solutions used in research and development with an integrated solution set for end-of-line NVH quality testing in manufacturing. The technology and team will join the Siemens PLM Software business, part of the Siemens Digital Factory Division, and will be incorporated into the Simcenter portfolio of simulation and testing solutions. With ever-increasing pressure on improving quality, the need for NVH type end-of-line testing for manufactured products such as electric motors, combustion engines, transmissions, axles, and turbo chargers is rapidly increasing across the automotive and transportation industries. This phenomenon is accelerated with the ascent of electric vehicles which have a low general noise level and are lacking the masking effect from a loud combustion engine. “With the integration of Saab Medav NVH quality testing solutions, Siemens customers can gain the ability to enrich the digital twin of their product design with continuous quality control information from manufacturing. This provides unique insight in how production technology and variability in manufacturing lines influence the final product quality,” explains Jan Leuridan, Senior Vice President, Simulation & Test Solutions, Siemens PLM Software. “The technology also gives direct feedback on the root cause analysis of possible design […]

5 Mpixel CMOS image sensor ideal for high-speed scanning and embedded vision solutions

Teledyne e2v, a Teledyne Technologies company and global innovator of imaging solutions, announces the expansion of its Snappy family of image sensors with a new 5 Megapixel device. The SnappyTM 5M is designed for barcode reading, 2D scanning and other demanding applications. Available in both monochrome and color, the Snappy 5M has a small 1/1.8 inch optical format, containing a 2.8 μm, low-noise, global shutter pixel, and arranged in a 2,560 x 1,936 array. The device can stream video at ~50 fps at 10 bits over a 4 wire, MIPI CSI-2 interface, and is housed in a small compact fan-out organic package. Snappy 5M is designed to enable fast, extended range scanning and includes powerful unique patented features and region of interest modes: • A Fast Self Exposure (FSE) mode automatically calculates the optimum integration time that is applied to the first image from the device. The mode is user programmable and provides continuous fast decoding, tolerating any kind of lighting or dynamic lighting environment. This is advantageous compared with conventional auto exposure methods, improving convergence speed and robustness. • A Smart ROI feature searches for barcodes in the image frame, and reports their locations as metadata in the image footer. The regions of the image containing barcodes are discerned from the background image to considerably reduce downstream image processing (FPGA/CPU/DSP) power, time and cost. Up to 16 different regions can be detected simultaneously. Other forms of repetitive signatures such as printed character strings can also be detected for document scanning and OCR applications. The Snappy family of sensors enable a number of applications including embedded industrial imaging systems, drones/UAVs, IoT edge devices, intelligent surveillance cameras and augmented reality/virtual reality. This latest 5 Megapixel device is a member of the expanding Snappy family of sensors. The sensors have identical software […]

Predicting the future of maintenance

In 1927, Thomas Parnell set up the pitch drop experiment, which examines the viscosity of a tar-like substance by the speed at which it flows from a funnel into a jar. The test has seen just eight drops fall in as many decades and, despite the experiment being displayed in the University of Queensland’s physics department, no one has ever seen a drop fall. Just like this test, the need for factory maintenance often goes unnoticed. Here Gernut van Laak, group automation solutions leader of ABB’s Food and Beverage Program, explains how plant managers can budget for maintenance and ensure optimum efficiency for all processes. Paper to glass In terms of research and development, food and beverage is a leading industry because of its use of new, innovative technology. However, when it comes to maintenance, many companies find themselves keeping paper records. While regulation and compliance requirements historically drove these companies to work with paper, advancements in digital tools mean this is no longer the case. Unfortunately, once paper-based systems are in place, they can be difficult to eradicate. Companies become stuck in their ways, which leads them to ignore the significant cost savings, efficiencies and competitive advantages electronic systems can provide. The most important driving force for a company’s success is its employees. Today’s maintenance engineers have the computing knowledge to make the switch to digital. Providing them with a familiar interface that quickly connects employees across the organization allows staff to work faster and smarter, increasing productivity. Electronic records also eliminate time-consuming and error-prone data entries that are necessary with paper-based systems. While staff are the most important factor of any company’s success, the biggest cost of manual maintenance comes from people. Human errors that occur during manual record-keeping can result in redundant actions, rework and audits. Electronic […]

Reaping the benefits of smart manufacturing

Manufacturers can have many hundreds or even thousands of endpoints in their network, from laptops, PCs, and mobile devices to networked production-line machines spread throughout the facility. These connected systems deliver operational efficiencies and even competitive advantage to manufacturers. Smart manufacturing has helped manufacturers achieve productivity gains of 17 to 20 per cent and quality gains of 15 to 20 per cent. However, smart manufacturing also introduces cyber risks, which must be addressed in the most time-efficient, reliable way, according to ForeScout. Steve Hunter, senior director, Asia Pacific and Japan, ForeScout, said, “In the past, production-line machines were air-gapped; they didn’t have a network connection, so they were safe from cyberthreats. Now, with every machine and device connected to the corporate network and the internet to facilitate smart manufacturing, that safety buffer is removed. Therefore, it’s essential for manufacturers to know what devices are in their network, how vulnerable they are, and their compliance status. All endpoints, including Internet of Things (IoT) sensors, need to be secured.” In many industries, endpoint management is conducted using agents, with IT departments choosing a combination of agents to address their specific requirements. However, the use of agents can create performance issues in manufacturing operations, meaning an agent-based approach is not well-suited to manufacturers. When networked operational or production-line devices are scanned, it can impair performance, reboot the device, or even crash it entirely. This causes expensive downtime. These devices are often vulnerable because they’re older, rarely patched, and less protected against threats. Even new IoT devices can become exploited, because they’re generally not designed with security top of mind. These new IoT devices are often deployed without configuring the few security settings available to them, such as leaving default credentials in place. This lets malicious actors use the unsecured IoT device to access […]

Hypertherm introduces new consumable kits for XPR cutting systems

Hypertherm, a U.S. based manufacturer of industrial cutting systems and software, is shipping consumable kits for its XPR X-Definition Plasma systems. These new consumable starter kits are available with or without a torch for mild steel and non-ferrous cutting applications. The kits include a variety of consumables to allow for cutting at different amperages, using all of the gas process types supported by the XPR170 and XPR300 bsystems. The consumables contain several patent pending technologies to improve consumable life and cut quality. Examples include Cool nozzle and Arc response technology, the latter of which protects consumables from the negative impact of ramp down errors, a regular occurrence in real-life cutting. By reducing the impact of ramp down errors, XPR consumables can last up to three times longer than those on older generation systems. In addition, XPR consumables are designed with ease of use in mind. An EasyConnect feature allows operators to quickly plug the torch lead into the torch connect console without the use of tools, while a patent pending QuickLock electrode delivers easy quarter turn tightening to further reduce setup time. Another new design feature is a quick change torch that enables an operator to rapidly change torches with just one hand. “Whether you are cutting mild steel, stainless steel, or aluminum, these new starter kits will make it easy for XPR customers to get all of the consumables they need in one convenient kit,” said Martin Geheran, product manager for plasma torches and consumables. “We think customers will also enjoy the convenience of the kits that come with a torch as it will give them the option of having a second torch, or even multiple torches, pre-loaded with consumables for even faster change-outs.” Hypertherm designs and manufactures industrial cutting products for use in a variety of industries such […]

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