Manufacturing Technology

Innovation hub to fast-track Industry 4.0

An innovation hub to help Australian companies make the shift from traditional manufacturing to more advanced, value-added products has opened in Adelaide. The Tonsley Manufacturing Innovation hub in Adelaide is designed to accelerate the national adoption of ‘industry 4.0’ technology among hi-tech and manufacturing businesses, as well as foster research and development. The hub’s February 9 launch in the South Australian capital comes at a time when the nation’s economy is transitioning from a traditional manufacturing base to more digitalised, knowledge-based industries following the closure of Holden’s Adelaide plant late last year, which brought an end to automotive manufacturing in Australia. Professor John Spoehr, Director of the Australian Industrial Transformation Institute at Flinders University, said the adoption of new age digital technology was crucial due to the highly competitive environment of manufacturing internationally. “Without the automotive industries we need new sectors and new industries that will be at the forefront in the uptake of new technologies,” he said. Professor Spoehr said the hub would enable closer collaboration between educational organisations and businesses to better understand digital technology in new age manufacturing and its impact on the performance of companies and workers. The term ‘industry 4.0’ refers to the growing trend of automation and the use of the Internet of Things, Cloud computing and cyber-physical systems in advanced manufacturing. Situated on the ground floor of the Flinders University building at Tonsley, one of the key facilities at the Tonsley Manufacturing Innovation hub is the modular Future Factory. Made in Germany by technology giant Festo and funded by the South Australian Government, it showcases the latest automation, sensor, monitoring, robotic and cobotic technologies and is one of only a few Future Factories in the Southern Hemisphere. Professor Spoehr said the platform was modularised and could be reconfigured in a variety of ways. “It’s a great education […]

Hugely durable Wearply outstanding for materials handling and electrical tasks

Wearply from Cut To Size Plastics is used for applications ranging from insulated rail joints, above, through to vibratory conveyor leaf springs used in processing and loading equipment as well as electrical motor, generator and transformer components. A hugely durable reinforced plastic composite that weighs less than aluminium but has up to 10 times the specific strength of 1020 steel is being offered by Cut To Size Plastics for demanding rail, ports, mineral processing, materials handling facilities, infrastructure construction and associated electrical and industrial applications. Wearply reinforced plastic composite is ideal for maintenance, engineering and fabrication tasks which aim to optimise design and performance of infrastructure and machinery components and leaf spring assemblies in which performance and reliability is vital. Wearply can withstand millions of stress cycles at 1400 bar (20,000 psi) without fatigue failure. Wearply derives its enormous strength, performance and durability from epoxy resins reinforced with continuously aligned, non-woven filaments. This allows plies to be laid so reinforcement is oriented to give greater strength and stiffness in the direction, or directions, in which it is most needed. Parallel filaments resist the stress abrasion that can shorten the fatigue life in conventional reinforced plastics. “This advanced engineering material is winning the attention of machinery designers globally for its superior performance in a huge range of applications, from rail, materials handling facilities and associated electrical plant through to vibratory machinery in minerals and primary production processing and loading applications. “The same qualities that make it suitable for advanced aerospace and medical applications – such as helicopter blades and MRI equipment – mean it can be employed with confidence in rail, materials handling, marine and ship loading and high-precision tasks where reliability is vital,” says Mr Flood, who has national and international experience in the application of light but outstandingly durable […]

New frontiers for South Australian space industry

The International Astronautical Congress hit Adelaide in 2017, bringing more than 4500 space experts to town and the focus of the world on South Australia. Jim Plouffe The Hubble Space Telescope being serviced as the Space Shuttle crosses South Australia in December 1993. Picture courtesy NASA.Although the IAC was the culmination of a decade of work by many people in Australia’s space industry, it can also be seen as the launching pad for a revitalised space industry based in South Australia. The Australian government used the congress to announce that Australia would finally have a national Space Agency (pending yet another review due in March 2018) while Elon Musk used the congress to tell the world he was putting all his resources toward developing his BFR to not only travel to Mars but also to reduce earth travel times to under an hour and establish a lunar base. Michael Davis, the Chair of the Space Industry Association of Australia, said organising the congress made South Australia a leader in space industries and the South Australian government’s space plan would help the state influence the new National Space Agency. “The South Australian government backed our bid [for the congress] right from the beginning, going back eight years,” he said. Heads of space agencies, from left, NASA Acting Administrator Robert Lightfoot, Russian Federal Space Agency (Roscosmos) Head Igor Komarov, European Space Agency Director General Jan Woerner, China National Space Administration (CNSA) Secretary General Tian Yulong and Japan Aerospace Exploration Agency (JAXA) President Naoki Okumura at the International Astronautical Congress in South Australia. “When we won the bid, they saw the opportunity. They didn’t wait till the congress took place, they formulated and implemented a strategy that has led directly to the announcement of the South Australian Space Industry Centre and the $4 million in funding.” A week […]

Production automation opens up new opportunities for thermoplastics

As production automation seeks to drive down the cost of manufactured and processed products, machinery engineers must find materials that enable their designs to achieve faster, more efficient and more reliable applications. The search for high performance materials that are also low cost, safe and sustainable has led some producers away from traditional metal solutions and into engineered thermoplastics, which can in many cases be carefully formulated to precise and clean, green performance characteristics for applications. One example of such new age materials offering outstanding service life as OEM and metal component replacements is the Wearlon family of thermoplastics from Cut to Size Plastics, which are used for machine building, process automation, drive and conveyor equipment and ancillaries used in such industrials as food and beverage processing, manufacturing and materials handling. There is much more research going on now into the correct materials to use for production automation, because it is a major investment that may be key to a company’s future. So it is no longer good enough to do things the old way they have always been done, because the rate of change in automation is accelerating and it would be very easy to be left behind completely. Sometimes change is driven in automating industries by pure economics, while, in other cases, issues such as HACCP food safety requirements are important. It is important to say there is no one ideal answer to all applications – whether they be metals or engineering thermoplastics – but it is certainly essential to consider all the options. Where required, Cut to Size can draw on the globally respected expertise of its international suppliers, including Licharz GmbH, producer of Linnotam and other members of Cut to Size’s Wearlon family of polyamides. Licharz’s applications laboratories and […]

Remote-controlled trolley-collector wins award for ‘Game Changing’ Innovation

A Melbourne engineering company, Lockelec Innovations, has solved the problem of wayward supermarket trolleys, with a Bluetooth remote controlled trolley collector, the Red Rover. The bane of supermarket operators worldwide is the manual collection of the ubiquitous supermarket trolleys scattered throughout car parks. Not only is the practice of collecting the trolleys labour intensive and unproductive, it results in numerous injuries and costly Workcover claims. Coles supermarkets, conscious of the ‘trolley problem’, scanned the world for technology which would make the collection of the trolleys a simpler, more ergonomic process. After an exhaustive search and numerous prototypes, Coles chose Braeside-based engineering company Lockelec Innovations to create a solution. After twelve months of developments and trials, Lockelec’s remote-controlled (Bluetooth) ‘Red Rover’ was born. The innovation recently won Coles’ Rising Star award for Supplier of the Year, which was accepted in Melbourne by Lockelec Managing Director Stuart Lord, a third generation owner of the Braeside company. ‘We genuinely love the challenge of finding innovative solutions by thinking out of the square and were thrilled to have Coles’ support,’ Lord said. ‘The Red Rover is a Game Changer because it reduce manual handling (of trolleys), makes the workplace safer and is much more efficient.’ (Lockelec leads the world with their compact lithium-powered electric motors and a range of innovative technology solutions to make workplaces safer and more productive;- in hospitals around the world, hotels, supermarkets, banks and even the MCG). The ingenious Red Rover trolley-collector removes the manual-handling hazards involved in trolley collection and results in significant productivity improvements. A staff member provides direction of the ‘trolley train’ by simply guiding the lead trolley in the desired direction, while the Red Rover provides silent, motorised pushing power from behind. Innovation has been a part of Lockelec’s fifty year, three generational culture which has […]

Does the role of the engineer need to be re-imagined?

Engineers today face multiple, increasingly complex challenges. The need for future-proofed infrastructure, the impact of automation, intelligent buildings and new infra-technology to better design, build and manage our assets – will all require an extremely high level of innovation. Engineering and infrastructure advisory firm Aurecon’s focus has been on re-imagining engineering through leadership in design – and it’s a focus that has seen two of its engineers recognised on this years Engineers Australia’s ‘2017 Most Innovative Engineers list’. Tony Lavorato, Structural Technical Director at Aurecon, was recognised for his work on 5 Martin Place in the Building & Construction Category, while Stephen Logan, Design Director – Building Mechanical & Electrical (MEP) at Aurecon, was recognised in the Consulting Category for his work on Sunshine Coast University Hospital. Dr Kourosh Kayvani, Global Director – Excellence & Expertise at Aurecon, adds that Tony and Stephen’s outstanding work exemplifies Aurecon’s new and more thoughtful approach to re-imagining engineering through leadership in design. He says, “As the world becomes increasingly complex, ambiguous and volatile, creative and innovative design must underpin the way we frame and solve problems facing humanity and our environment. “We are re-imagining engineering, and we are steadfast in bringing this idea to life for our clients as a new brand of engineers and innovators.” The citations were awarded by Engineers Australia in recognition of engineers who have made noteworthy contributions to the community, the industry and the engineering profession. Engineers Australia, with over 100 000 members, is the largest and most diverse professional body for engineers in the country. Re-imagining a heritage building For Tony, out-of-the-box thinking paved the way to solving the unique challenge facing 5 Martin Place. “This project is by far the most complex in terms of engineering gymnastics of any building that I’ve ever been involved in. The ‘smarts’ […]

Letting our capes fly: Why engineers are awesome

This glimpse of the future was crafted by: Michelle Doolan You don’t have to sit a 5-year old down and teach her the physical and psychological benefits of building forts. Chances are she has wrecked your lounge many times before. Written into the defaults of our DNA is the impulse to create ̶ to bring something that never was into being. Take away the plastic weapons of mass destruction from your toy box, and watch your toddler turn his peanut butter sandwich into a gun. Beach sand becomes castles; snow days invite igloos; the world is a wonderful palette that kids just intuitively want to paint on. Essentially, the engineer is hidden inside all of us. The question for us engineers who still hold the title is, are we still living like one? Because we may need to be reminded from time to time, the job of an engineer is a great one. By comparison to some of the other professions, engineering is often not seen as the “cool” one. TV shows like LA Law and Boston Legal glamorise legal eagles battling it out in high profile court cases. ER, House and Scrubs bring the world of medicine into our living rooms. Even Grand Designs puts architecture on a pedestal. Isn’t it about time that TV producers got in touch with the profession that is shaping the future world we live in like no other? As a discipline, it lies at the very fabric of our society, shouldering the systems and spaces that give our world its meaning. Too often the profession is associated with hard hats and tool belts, viewed as difficult and esoteric. But in reality, engineering is a far cry from ‘restrictive’ and ‘routine’. It is alive and multidimensional, unleashing the power of connected societies to unlock […]

Metso partners with RA to create IoT solutions for mining

Metso has selected Rockwell Automation to deliver a global industrial Internet of Things (IoT) platform that connects, monitors and performs analytics for Metso’s equipment and services, resulting in improved efficiency and profitability for its mining and aggregates customers.  The digital solution will securely collect and store data from Metso’s equipment around the globe, including new equipment and machines already in operation. The solution will provide predictive analytics and preventive maintenance, and facilitate remote asset monitoring by Metso and its customers. The industrial IoT solution is built on the FactoryTalk Cloud platform from Rockwell Automation, powered by Microsoft Azure. Rockwell Automation and Microsoft have long collaborated on solutions required for industrial digital transformation. The Metso solution is a direct result of these efforts.   “For our mining and aggregates customers, access to real-time data enables higher uptime, faster and safer shutdowns, and ultimately more tonnage processed at lower cost. Enabled by an industrial IoT platform from Rockwell Automation and global coverage with Microsoft Azure’s data centres, Metso can deliver analysed equipment data into the hands of its customers for advanced decision-making,” says Jani Puroranta, chief digital officer, Metso.   Metso began working with Rockwell Automation on a pilot program in 2015, remotely monitoring an African-based mining crusher from a location in Wisconsin. Metso was immediately able to use the data collected to identify opportunities for improvements in machine performance. The quality of the solution and support Rockwell Automation provided during the pilot gave Metso confidence that a broader implementation of the industrial IoT platform would drive the results it was seeking on a global scale. “Metso has an inspiring vision to deliver powerful analytics and information solutions in mining and aggregates that will drive business results for customers,” said Blake Moret, president […]

Medical devices give hope to traditional manufacturers

By Caleb Radford Manufacturing companies in Australia are finding niches in the medical technologies sector as their traditional markets of mining and automotive diminish. Lower production costs and more robust large-scale capabilities offshore are playing a major role in the exit of mining and automotive component manufacturers from Australia. However, industry and government support have helped some firms evolve their advanced manufacturing skills and enter the medical device market. Medical device production in Australia has grown by 1.3 per cent annually since 2012 and is now valued at AU$3 billion a year according to IBISWorld. South Australia is emerging as a hub for the medical devices industry and is home to the Tonsley Innovation Hub and the Adelaide BioMed City precinct, a $3 billion tripartite health hub comprising a major hospital, research centres and educational institutions. The Tonsley hub is located on the site of a former Mitsubishi car manufacturing plant and major tenants include medical device manufacturer Micro-X, Siemens and ZEN Energy. International optical and optoelectronics firm ZEISS is also about to move into a new $6 million premises at the hub. The downturn in world commodity prices has forced South Australian company Plastico and Hackett Engineering to shift its focus from mineral analysis equipment development to components for orthopaedic implants. The company first dabbled in medical devices in 2014 but has now decided to make it a major focus following collaboration with another Adelaide-based firm, Austofix. Plastico and Hackett Managing Director David Schiller said 20 years’ experience making mining components had it well placed to succeed in the medical field. “The decline of the mining industry in Australia has forced us to look at other things,” he said. “China seems to be commanding a large chunk of the mining components manufacturing and we have seen our business move […]

Australia’s first certified flame-retardant polyurea coating

The economic impact of corrosion is often exacerbated in harsh climatic environments and in workplaces with heavy traffic wear from operation of large vehicles and equipment. Excessive moisture, heat and abrasion can accelerate the deterioration of machinery, vehicles and assets. Applying a protective surface coating is one way of minimising or reducing the effect. One coating material for harsh conditions—including those in a combat zone—supplied by Rhino Linings Australia (RLA) is Rhino Extreme 11-50 FR. While the material has been available for several years, it was only late in 2016 that the fire resistant nature of the product received certification. RLA’s Technical Manager, Robert Idzes, said “The formal certification of Rhino Extreme 11-50 FR has opened up a range of new opportunities for industrial and commercial applications of the product.” The spray-applied pure polyurea is suitable for any application, such as a fuel bund—secondary containment area—that requires a fire resistant surface. Historically, bunds have been constructed of concrete or brick, but in recent years have been coated with a spray-applied pure polyurea or welded plastic liner to prevent leaks. Fire is a potential hazard if a leak does occur, especially where fuel, sodium hydroxide, sulphuric acid and other highly flammable materials are stored. The flame resistant properties of Rhino Extreme 11-50 FR significantly reduces the burn rate allowing safety officers and staff time to extinguish the flames before major damage is caused to the liner or catastrophic failure occurs. “The Rhino Extreme 11-50 FR is the latest Flame Retardant product to meet US Federal Aviation Regulation 25 (FAR 25) Flammability testing for aircraft,” said Denis Baker, Special Projects Engineer at RLA. “In addition, it also meets UL 94, which is another high standard at the moment for coatings.” The FAR 25.853 tests the self-extinguishing performance of materials under fire conditions. […]

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