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Flange facing machines deliver fast and accurate performance

Enerpac Mirage OD mount flange facing machine Enerpac is introducing a new range of external mount flange facing machines designed for fast installation and accurate machining of large diameter flanges used in applications throughout Australia, New Zealand and Papua New Guinea. The new Mirage branded OD mount facers are the perfect choice for machining flanges 30” to 80” (762-2032mm) diameter in industries such as oil and gas plant, offshore platforms, refineries, LNG, pipe spool, heavy industrial fabrication, shipbuilders, EPC contractors, industrial plant, power plants, service and maintenance, says Enerpac Channel and Product Leader – Australasia, Mr Andrew Marsh. Applications also include facing heat exchanger flanges, maintenance projects, large flanges such as crane pedestals and flanges where bore mounting is not preferred. “The simple Outside Diameter (OD) mount configuration of the new machines overcomes industry reluctance to bolt ID mount flange facers to the inside of heat exchanger tubes,” says Mr Marsh. Each of the 6 machines in the range includes a continuous variable auto-feed which enables on-site machinists to create a wide range of gramophone-surface finishes to ASME standards (regulating the design and construction of boilers and pressure vessels). Robust construction and the inclusion of heavy-duty bearings ensure all machines deliver high metal removal rates whilst delivering accurate results. Easier and quicker machining “These new products provide all of the versatility to carry out different flange facing projects you’d expect from an Enerpac product, but, when used for heat exchanger refurbishment, they go a step further. “Convenience for the user has been taken to the next level by providing the clever ability to attach milling rails while the machine is still mounted in-situ,” says Mr Marsh. This innovative feature makes it easier and quicker to machine heat exchanger division slots. Machining the back face of flanges can also be carried […]

See and solve failures before they happen with predictive analytics

Wouldn’t it be nice to know when the devices in your home are on their last legs, so you could fix or replace them before they break? Just imagine how much better life would be. No more air conditioner breakdowns in the dog days of summer. No more unusable dishwashers on busy weeknights. No more computer crashes before you can back up your family photos and personal files. The same holds true for the plant floor. By knowing when machines and equipment are about to fail, you can proactively service them to avoid stressful situations like downtime, missed customer orders and quality issues. We may not know when our home technologies will be kaput. But such insights are possible in your production operations today using dashboards with predictive analytics. When real time is too late From smart machines to connected sensors, IoT technologies have forever changed how you see your operations. You can now access data and analytics that matter to monitor almost any aspect of production, in real time, around the clock. This data is great for tracking performance, quality and more. Real-time data is not enough, however, when it comes to spotting machine or equipment failures that cause unexpected downtime. You need insights into potential issues before they cause downtime, not after. This is where advanced analytics software and dashboards come into play. The software combines real-time data with machine learning to understand the patterns that precede downtime events and other issues. It’s presented in a dashboard and can detect anomalies that may indicate new failure modes or other issues that need to be investigated. These predictive insights can help your workers solve any number of challenges in your operations. Look into your future Even more valuable than knowing when something is about to fail is knowing what you need to do […]

OnRobot takes robot compatibility to the next level

New Digital I/O Converter Kit and Quick Changer for OnRobot end-of-arm tooling (EoAT) dramatically simplifies automation with a single platform for a full range of collaborative and light industrial robotic systems. OnRobot, a global leader in end-of-arm tooling (EoAT) for collaborative robot applications, has introduced two new products – the Digital I/O Converter Kit and Quick Changer – which together with other OnRobot EoATs, creates a unique One-System Solution that dramatically simplifies automation. OnRobot’s Digital I/O Converter Kit allows OnRobot EoATs to work with a full range of leading collaborative and light industrial robot brands. Building on that initiative, all OnRobot products now have a unified mechanical and communications interface based on the OnRobot Quick Changer, which is now an integrated part of all OnRobot products. An additional Dual Quick Changer incorporates these same new capabilities while allowing the use of two tools in one cycle, mixing and matching to suit application needs and maximising robot utilisation. Now, with a single robotic system, single platform for programming and training, and single vendor relationship, manufacturers have access to a full range of tools, full robot compatibility, and virtually unlimited possibilities for collaborative applications. This new one-system solution speeds deployment so manufacturers save time and money and can quickly realise the benefits of automation. Manufacturers are demanding more from their robotic applications, and end-of-arm tooling has become the key to optimising their investments. This integration of the Quick Changer across the current product lineup makes it easier than ever to switch between tools and robot types, allowing flexibility and reducing downtime for more efficient production and faster automation ROI. This is another step closer to a unified OnRobot one-system solution that makes it easy, fast and cost-effective for manufacturers to build collaborative applications, no matter which robots they choose.” Unified platform across […]

The plural of plastic

-Natalie Martin, 3R Material Innovation Manager Plastic is a hot topic around the world these days, and so it should be. The terrible effects it has on the environment are undeniable, and there is evidence those effects are circling back to us. Plastic has also become something of the posterchild for society’s conspicuous over-consumption. But is plastic all bad? The short answer is actually, no. Plastic – first developed by British inventor Alexander Parkes in the early 1860s – was hailed as something of a miracle substance. Light, durable, easy to sterilise, cheap to make – the list of positive properties is impressive. Without plastic the world would be a very different place than it is today – simply consider how many things are made, at least in part, of plastic. It’s probably easier to think of how many things are not. It is of course some of those very same properties – namely its durability – which have made plastic an environmental disaster. Combine this with a single-use, throw away culture around plastic and there is a serious problem. But plastic is recyclable, isn’t it? Well it is, and it isn’t. This is because one of the biggest issues is plastic isn’t just one substance – it is in fact a complicated web of different types and grades, each with different properties and applications. Broadly speaking plastics fall into two groups – thermoplastics, which can be remoulded with heat, and thermoset which cannot and need other processes, such as the use of chemicals. The most commonly used plastics have been assigned identification numbers which identifies the plastic types. These range from 1 to 7 with category 7 being the ‘all other’ or mixed plastics. This is where recycling becomes complicated. As you might imagine thermoplastics are easier to recycle […]

Software framework generates ISO programs for CNC machine tools

A powerful new software framework tool enables users of CNC machine tools to generate and test ISO part programs offline. The tool looks set to win across-the-board approval in busy machine shops, where an uninterrupted workflow can provide a key productivity advantage. Flexium Office framework software runs under Windows 7/8 or 10 on any standard PC. It allows any of NUM’s technology HMIs (Human-Machine Interfaces) to be used for specific projects – without requiring access to the target CNC machine tool. The corresponding ISO part program can be created offline and can also then be tested offline using NUM’s Flexium 3D simulation software, before being transferred to the target machine. Application-specific technology HMIs form part of the company’s Flexium CAM (Computer-Aided Manufacturing) software suite. The HMIs cover every type of CNC machining operation, including hobbing, shaping, milling, threaded wheel grinding and cylindrical grinding. After selecting the most appropriate technology HMI for the task, the user simply carries out basic data definition tasks for the project in hand, using the highly intuitive tools and workflow commands provided by Flexium Office. Multiple projects can be started and saved at any time – allowing collaborative team development if desired – and the framework software provides support for 14 languages. As soon as the user is satisfied with the process and workflow of a project it can be used to generate the corresponding CNC part program – entirely automatically. The CNC program can either be transferred directly to a nominated machine in the production plant, usually via a TCP/IP network, or input to NUM’s Flexium 3D simulation software for thorough evaluation before being issued for production purposes. The key advantage of simulation is that it enables users to optimise any ISO-code part program offline, further helping to maximise productivity by leaving the CNC machine […]

Siemens MindSphere on Microsoft Azure Private Cloud goes live

Solution allows deployment of industrial IoT applications in secure and private cloud infrastructure Users can optimise efficiency, availability and performance effectiveness of assets and processes Build modern apps with flexibility and control Siemens and Microsoft are jointly bringing the offering of Siemens’ MindSphere on Azure Stack, a cloud-based, open Internet of Things (IoT) operating system, to customers in Singapore. This solution allows customers to deploy industrial IoT applications in a secure, managed private cloud infrastructure. MindSphere connects products, systems, machines, and whole factories, enabling customers to harness the wealth of IOT data with advanced analytics. Microsoft Azure Stack brings the agility and innovation of cloud computing to on-premise, so organisations can build modern apps across their environment with the flexibility and control they need. MindSphere on Azure offers the best of both worlds —Siemens’ leadership in Industry 4.0 combined with Microsoft’s fast-growing cloud platform. Now the two companies jointly bring this offering to Singapore, to help customers here to optimise efficiency, availability, performance effectiveness of their assets and processes. Microsoft and Siemens have built a strong partnership over the years to bring leading innovations to customers that support digitalisation and Industrial Internet of Things. Steffen D. Endler, Head of Siemens IoT Digital Consulting in ASEAN notes, “We’re seeing high interest and adoption of private cloud across a number of sectors including manufacturing, utilities, critical infrastructure and healthcare. This makes perfect sense, as these sectors have some of the most stringent regulatory requirements and typically also some legacy systems. These customers, whose data cannot leave the borders of the country or even of the premises, but who nevertheless want to benefit from a proven IoT platform and want to utilise existing cloud-based IOT applications can deploy this with such an innovative solution.” Siemens IoT Digital Consulting offers customers a one-stop contact […]

Datalogic enhances robot guidance and traceability with Impact software

Datalogic’s latest IMPACT software enhances performance and traceability for vision-guided robots and cobots. Datalogic, a leader in robotics, Industry 4.0, automatic data capture and process automation, is introducing its new Impact 12.2 software to further enhance the traceability and ease-of use of vision-guided robots and cobots used for a wide variety of pick, place and other vital production line tasks. The new robot guidance and traceability software is available throughout the Asia-Pacific region and incorporates a number of calibration and performance enhancements to make robot programming faster and simpler, as well as improve accuracy and traceability. “With Datalogic’s Impact 12.2 system, robots can now be deployed faster, and they are more adaptable to changing applications in dynamic industries such as warehousing, logistics, supply chain, manufacturing, automotive, healthcare, transport and OEM markets,” said Mr Bradley Weber, Product Marketing Manager – Machine Vision, Datalogic. “The latest software has been thoroughly tested in conjunction with leading robotics company Universal Robots and has been fully approved and UR+ certified to work their robots and cobots. UR+ certification means they have the full technical support and expertise of the Universal Robots team, as well as access to their highly customisable software,” said Mr Weber. Collaborative robots, or ‘cobots’ work harmoniously with people in production and distribution operation such as pick-and-place and production lines. Often, the robot performs repetitive tasks requiring strength or precision, while the person guides the robot to the right place, provides a part for it to pick, or performs other tasks that complement the robots programming. According to Universal Robots, “Cobots give manufacturers access to all the benefits of advanced robotic automation, without the extra costs associated with traditional robots: difficult programming, long set-up, and shielded work cells. This makes automation affordable even for small-batch production runs and mixed product assembly.” Software […]

Is 5G ready for manufacturing?

High profile scandals aren’t typically good for the technology sector. Whether it’s diesel emissions, large data breaches or cyber-attacks on mission-critical infrastructure, scandal has the power to cripple a technology even before it’s gotten off the ground. Despite what recent headlines may have you thinking, 5G has the potential to be a hugely positive force in the world of manufacturing, heralding in a new era of technological innovation. While 3G and 4G offered incremental improvements in speed and bandwidth, 5G will be the first cellular, wireless platform to truly offer reliable integration with machine-to-machine and industrial IoT systems. It will do this in three ways. The first is enhanced mobile broadband (eMBB); 5G offers peak data rates of 10 Gbps and can handle 10,000 times more traffic than its predecessors. Secondly, it offers Ultra Reliable Low Latency Communications (URLLC). This means it has a radio latency of less than 1 ms and an availability of over 99.9 per cent, making it ideal for industrial use where uptime is critical. Thirdly, it offers Massive Machine-type Communication (eMTC), allowing it to handle a density of one million devices per square kilometre. It can also deliver ultra low-cost machine-to-machine communications and can last up to 10 years on battery, great for battery operated low power devices. So, what does this mean for industry? Well, not only will 5G open the door for real-time wireless sensor networks and location and asset tracking, it will also enable plant managers in smart factories to rely on seamless communication with a fleet of autonomous guided vehicles (AGVs) without worrying about network dropouts. What’s more, manufacturers that may have been sceptical of adopting the likes of augmented and virtual reality technologies will be able to take full advantage of them for real-time simulation and predictive maintenance. In industrial […]

Composites for car part manufacturing

The US Environmental Protection Agency (EPA) mandated in 2012 that the national automobile fleet should average 54.5 miles per gallon by 2025 in order to reduce reliance on fossil fuel and minimize emissions, many other nations have also implemented similar new standards. To meet these new standards the automotive industry has had to find new ways to make lighter cars without sacrificing their strength and structural integrity. Here Jari Sopanen, Regional Manager at leading composites manufacturer Exel composites explains why one of the best replacements for steel is thermoset components. Thermoset composites are formed using glass, carbon, or aramid fibres, which are then combined with resins such as polyesters, vinyl esters, epoxies, or phenolic resins. These composites are used in various industries but are particularly prominent in the manufacturing of aircraft and spacecraft parts. Thanks to research and development in the aerospace sector, composites are also being used across other forms of transportation due to the high demand for lightweight vehicles and components. This trend, called light-weighting, seeks to use innovative materials to reduce the weight of products. As a result, composite materials are being increasingly used in production, especially for automotive parts and components. According to the American Composites Manufacturers Associations, fiberglass is one of the key reinforcing materials used in the US thermoset composites industry. Thanks to its durable properties, it is a good replacement for steel in vehicle structural components, including drive shafts, bumpers and roof beams Reducing component weight is crucial for raising the efficiency of automotive systems. For example, carbon fibre has comparable properties to steel, but is only one-fifth the weight. Regardless of the mode of transport, it is easy to see the benefits that shaving this amount of weight from a vehicle will achieve. Additionally, when directly compared to steel, composite materials can […]

Update of Hypertherm’s Robotmaster robot programming software available

Hypertherm has released Robotmaster Version 7.1, a major update to the completely redesigned and advanced architecture of its Version 7 software released last year. In total, this new robotic programming software contains more than 40 new features, 500 improvements, and dozens of bug fixes. Many of the changes, driven by customer feedback, are designed to continuously improve the software’s CAD/CAM technology and automate programming, allowing customers to enjoy the best error-free robotic path in just one click. Added features and improvements include: Ability to automatically recognise weld joints embedded in CAD models which simplifies and speeds up programming Ability to transform operations to reduce multiple manual selections Ability to modify operation geometry (a section of the path or the entire path) so the user can match the CAD model to the actual part when a mismatch exists Robotmaster can handle both simple and complex robotic tasks, from straightforward plasma cutting jobs, to deburring and additive manufacturing applications. Today, Robotmaster software is used on robots that drill airplane fuselages, polish automotive dies, cut material, support additive manufacturing, and add value to a multitude of processes at family-owned job shops around the world. “Our goal was to revolutionise the way robots are programmed by creating software that is so intuitive anyone can use it,” explained Garen Cakmak, leader of Hypertherm’s Robotic Software team. “It enables customers to enjoy error-free task-based programming that takes collisions, singularities, joint collisions, and other robotic errors into account before running the program live on a robot. “This in turn makes it possible to program new jobs without interrupting the robot, minimising downtime and instantly increasing productivity and profitability.”

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