Smart Manufacturing

Universities’ employ hydraulics to test concrete screw anchors

Australian university researchers are working to enhance safety and predictability in concrete construction projects by testing the strength and resistance to pull-out failure of screw anchors increasingly used in Asia-Pacific building, construction and infrastructure projects. The researchers at Edith Cowan University (WA) and Swinburne University of Technology (Vic) are using powerful Enerpac industrial hydraulics to test, measure and accurately predict the tensile loading capacity and failure point of screw anchors used to connect structural and non-structural elements to concrete. The series of hundreds of tests involved in the ongoing programme use an Enerpac RRH307 double-acting 30-ton capacity hollow pull-cylinder mounted in a reaction frame with load cells, displacement transducers andstrain gauges to measure results of multiple tests, including predicting the tensile strength of screw anchors failing under pull-out failure mode. The test rig developed by the School of Engineering researchers from both universities is powered by an Enerpac ZU Series portable electric pump with a powerful 1.25kW universal electric motor featuring high oil flow and bypass pressure. This provides the portability, reliability and power-to-weight ratios required to conduct multiple tests to the point of bolt destruction in many cases. The hydraulic tools involved are the same types used extensively in demanding industries using screw anchors, including building and construction; infrastructure and civil engineering; road and rail bridges and other structures; and mining, oil and gas and bulk handling facility construction and testing. The testing conducted by the two universities involves multiple types and diameters of screw anchors, using concrete of different compressive strengths and age. Aspects of the research compare results achieved in experiments with the predicted values of the Concrete Capacity Design (CCD) method. Test method A reaction frame with a clear span of 500mm was used to support the hollow cylinder jack and a hollow load cell. According to ETAG […]

Manufacturing finalists announced in Victorian Premier’s sustainability awards

A world’s first emissions report for the manufacturing sector and two very diverse manufacturers and have been announced as finalists in this year’s Victorian Premier’s Sustainability Awards. Beyond Zero Emissions’ Electrifying Industry, finalist in the new Environmental Volunteering category, is a report by expert volunteers that shows how to eliminate greenhouse gas emissions from manufacturing. Downer is a finalist in the Large Business category. In partnership with Close the Loop and RED Group, they have created an asphalt pavement material, known as Reconophalt, that incorporates non-traditional repurposed materials to reduce environmental impact without compromising product performance. The asphalt mix also remains perpetually recyclable. (See picture below.) Retub has been announced as a finalist in the Small and Medium Enterprises category for their program Premium Reusable Takeaway Containers. Retub™ is a modern reusable take-away food container that reduces waste in up to three different ways and uses a unique, built-in container exchange program, Reswap. The Premier’s Sustainability Awards is one of Victoria’s major sustainability programs, celebrating people working to reduce the impact of climate change and to create a better future for us all. The interim CEO of Sustainability Victoria, Carl Muller, congratulated finalists for their innovative work, building a more sustainable environment for current and future generations. “Delivering these Awards means we continue to discover and celebrate the talent and enthusiasm Victorians have for thinking creatively about new models of sustainability,” he said. “The Awards, now in their 17th year, acknowledge leadership, innovation and achievement. Each finalist is commended for improving sustainable outcomes across business, government, education, health and within the community.” Winners will be announced at the Awards ceremony on Thursday 10 October at Forum Melbourne. The Premier of Victoria, Daniel Andrews, will personally select the winners of the Premier’s Regional Recognition Award and the Premier’s Recognition Award, which […]

Sealing skills focussed on medical problem solving

A company dedicated to solving complex challenges involving seals and interfacing components involved in health care, hospital, scientific and laboratory technology is expanding its services in response to growing demand. CSGtech has expanded into larger national headquarters in Rydalmere, Sydney, sharing more extensive research, engineering and distribution facilities with its parent company Air Springs Supply, which is a long-established Australian leader in actuation and isolation technologies, including Airmount isolators used beneath operating tables and sensitive computerised equipment. CSGtech (new website: www.csgtech.com.au) partners with clients in diverse areas of the medical and scientific community to customise high performance solutions for complex problems where seals and interfacing components must achieve durability, reliability and precision in analytical, therapeutic, surgical and research equipment, says CSGtech Manager, Mr Vinh Lam. “Sometimes the issues we address involve correct sealing of technology from ambient conditions, while in other cases they are directed at ensuring reliability and durability of wear components in service. In both cases, small but vital seals and interfacing components must be correctly specified to cope with chemicals, gases, liquids and harsh operating environments.” Mr Lam heads an expanded Sales and Technology team which brings together under one roof decades of experience in process engineering, problem solving, product development, proving and production. The team also provides expertise to CSGtech sister company Thomson Rubber Products. “Our expanded network of internationally accredited manufacturers enables us to supply an exceptionally high level of product, extending from specialist O-rings to moulded rubber fittings, fasteners and castings.” he says. “Correct seals and interfacing components are integral to a huge range of medical, healthcare and scientific technology, where they must be absolutely correct for purpose, traceable and achieve compliance with local and global standards for manufacturing, clinical, therapeutic and laboratory applications. Often the application involved may be non-standard standard technologies, where […]

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CSIRO Australian National Outlook 2019

Australia’s future prosperity will require bold action on a number of fronts and a deliberate commitment to careful and considered long-term thinking. Author James Deverell, Director, CSIRO Futures Australia’s future prosperity is at risk unless we take bold action and commit to long-term thinking. This is the key message contained in the Australian National Outlook 2019 (ANO 2019), a report published today by CSIRO and its partners. The research used a scenario approach to model different visions of Australia in 2060. We contrasted two core scenarios: a base case called Slow Decline, and an Outlook Vision scenario which represents what Australia could achieve. These scenarios took account of 13 different national issues, as well as two global contexts relating to trade and action on climate change. We found there are profound differences in long-term outcomes between these two scenarios. In the Slow Decline scenario, Australia fails to adequately address identified challenges. CSIRO, Author provided The Outlook Vision scenario shows what could be possible if Australia meets identified challenges. CSIRO, Author provided Slow decline versus a new outlook Australia’s living standards – as measured by Gross Domestic Product (GDP) per capita – could be 36% higher in 2060 in the Outlook Vision, compared with Slow Decline. This translates into a 90% increase in average wages (in real terms, adjusted for inflation) from today. Australia’s real GDP per capita in 2016, and the modelled outcomes for Slow Decline and Outlook Vision. In Outlook Vision, the darker shade shows outcomes under a cooperative global context and the lighter shade under a fractious global context. CSIRO, Author provided Australia could maintain its world-class, highly liveable cities, while increasing its population to 41 million people by 2060. Urban congestion could be reduced, with per capita passenger vehicle travel 45% lower than today in the Outlook Vision. Australia could achieve net-zero emissions by […]

Gamma helmets new benchmark for welder safety

Kemppi has launched its new Gamma range of helmets for welders The personal gear offers welders the best protection for the eyes, face and respiratory system, and it also integrates work lights for clear vision and safety in low light working conditions. The Gamma range reduces work fatigue, increases comfort, and helps guard against welding related health hazards. Designed to deliver maximum protection and safety for welding professionals, the Gamma family now sets the global benchmark. Intense light and heat from the welding and cutting arcs are known hazards in welding workshops. However, welding also contaminates the surrounding air. Welding and cutting fumes, which contain dangerous elements that are generally not visible to the naked eye, pollute the breathing air and can pose serious health risks. Typically, welders can breathe 4,000 litres of air in an 8-hour work shift, and if the lungs are unprotected, tiny fume particles can pass deep into the lung structure and can cause serious health risks through long and short-term exposure to the contaminated air. The new Gamma series protects welders from 99.8% of airborne fumes and particulates. ‘The Gamma series, when used together with the new powered filter unit, meets the highest European Total Inward Leakage (TIL) classification for respiratory performance, class TH3 as well as Australian and New Zealand standards,’ said David Green, Managing Director, Kemppi Australia. “This places the Gamma series in a category all of its own when it comes to delivering maximum overall protection for the welder.” Powered from either a battery powered filter pack or an airline breathing source, the Gamma GTH3 respirator models work on the ‘positive air pressure’ principal to exclude dangerous welding fumes, and supply clean and fresh breathing air into the breathing zone. These helmets ensure the welder enjoys a safe, cool and comfortable breathing […]

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 […]

Marr Contracting awarded contract on world’s longest bridge

Australian-based heavy lifting tower crane specialists, Marr Contracting Pty Ltd (The Men From Marr’s), have been awarded the contract to deliver specialized heavy lifting crane services on the construction of the 1915 Çanakkale Bridge and Motorway Project in Turkey. Joint venture project leaders, DLSY Joint Venture awarded the contract to The Men From Marr’s after a competitive tender that saw some of the world’s leading craneage companies submit proposals to be part of the high-profile project. DLSY Joint Venture partners; Daelim (Korea), Limak (Turkey), SK E&C (Korea), and Yapi Merkezi (Turkey) – won the contract in January 2017 to design, construct and operate the EUR 3 billion project for a 16-year period, after which time ownership will be transferred to the Administration, General Directorate of Highways, Ministry of Transportation and Infrastructure of Turkey. The 1915 Çanakkale Bridge is part of the Malkara-Çanakkale Motorway Project. The 1915 Çanakkale Bridge which spans the Çanakkale Strait in Çanakkale Province, joins the towns of Gallipoli on the European side of Turkey to Lapseki on the Asian side and is part of the Malkara-Çanakkale Motorway Project – a 88-km segment of motorway planned between Kınalı and Savaştepe that will link several motorways arriving from Thrace and Anatolia at the Canakkale Strait. The bridge is named in honor and remembrance of the World War One that took place between Turkish and Allied forces. The ambitious Project will play a pivotal role in connecting Western Turkey, providing a new heavy transit alternative to the Istanbul Strait passage that will not only mean faster and more cost-effective freight transport to the region, but strengthened economic potential and social bonds for its population. On completion the 1915 Çanakkale Bridge will be the world’s longest span suspension bridge. With a total bridge length of 4,608 meters, a central span of […]

Engineers discussing notes on factory stairway

Be at the cutting edge of global innovation

With changing consumer and business demands bringing greater competition to global markets, companies in New Zealand’s engineering and manufacturing sectors must consistently evolve in order to win new business and succeed. A term that has saturated global markets for the last decade is Industry 4.0 – the digitalisation of manufacturing. What we are in fact witnessing is an industrial renaissance that is changing the way we do business through the unification of real and virtual worlds, laying the foundation for the future of manufacturing with platforms that enable data and digital continuity to maximise innovation, collaboration with the extended enterprise, and improve profit margins. This Industry Renaissance has enabled global connectivity on an unprecedented scale, which Invenio has witnessed in its network of dynamic New Zealand businesses of all sizes that enjoy success locally as well as globally. Taking advantage of this opportunity requires the right tools to be implemented, such as the Dassault Systèmes 3DExperience platform and modelling, simulation and collaboration applications such as Catia, Delmia and Enovia. The 3DExperience platform enables organisations to move from siloed designs and a document-based approach to a unified platform that is data-driven and model-based. Combining multi-physics, behaviour-modelling, big data analytics and social collaboration on a single, digital innovative platform, New Zealand businesses can quickly respond to a fast-changing industry landscape. Designers can bring their ideas to life with Catia applications, the world’s leading product design and experience solution including world-class 3D modelling performance and simulation capabilities. Information is communicated through the Enovia application data management platform, allowing designers to efficiently collaborate across departments. Finished designs can be fast-tracked towards production with Delmia’s digital manufacturing solutions, enabling manufacturing efficiency through the digital planning, simulating and modelling of production processes. Invenio’s partnership with Dassault Systèmes has also enabled the success of a number of […]

The fourth industrial revolution and the factories of the future

After a decade of flat productivity, the arrival of the Fourth Industrial Revolution (4IR) is expected to create up to $3.7 trillion in value to global manufacturing. A few years back, experts noted that changes associated with the 4IR would come at an unprecedented rate yielding incredible results for those who truly embraced them. Still, the hockey stick of benefits has not kicked in yet – while all companies are making efforts to adopt technology, most of the production industry (~70%) remains in pilot purgatory (where technology pilots last for extended periods of time, and companies do not take the final step of scaling up viable technologies). Less than 30% of manufacturing companies are actively rolling out Fourth Industrial Revolution technologies at scale. The World Economic Forum, in collaboration with McKinsey, has undertaken a global search and assessment for “4IR production lighthouses” – sites representing the most advanced sub-section of the companies who are actively deploying 4IR technologies at scale. Leveraging these lighthouse sites, we will create an inclusive learning platform with aims on becoming the next “go-to” system for advanced manufacturing and bring the world closer to capturing the lion’s share of the benefits. The Fourth Industrial Revolution fundamentally transforms production Most manufacturing lines still look a lot the same way they did 10, 20 or even 30 years ago. Operators clock in, have a brief conversation with their crew and shift supervisor, and then operate a machine or tool for 8-12 hours before heading home. Depending on the day, the machine may break and need maintenance or an adjustment, the line settings may need to be modified for a specific product or run, or the operator may need to step away to resupply the line or be trained on a new procedure. In 4IR transformed manufacturing sites – production lighthouses – this is […]

Archer turns graphite into graphene

Archer Exploration Limited’s (ASX: AXE) independent collaborations between The University of Adelaide and Flex-G Pty. Ltd (FlexeGRAPH) have proven successful in developing graphene materials using a number of different approaches, including publicly available and proprietary methods. The University of Adelaide has developed materials including graphene powder and graphene oxide from Archer’s Campoona graphite using publicly available chemical and mechanical exfoliation processes. Alternatively, FlexeGRAPH has successfully prepared a water-based graphene material dispersion using proprietary methodology involving surfactant assisted exfoliation.Archer CEO Dr Mohammad Choucair commented: “We are confident in our capability to provide high-quality graphite that is process agnostic in the production of graphene. Regardless of avenue taken, our Campoona graphite resulted in graphene materials that demonstrate the structural integrity suitable for high value applications. The work with The University of Adelaide and FlexeGRAPH highlights our continued and successful collaborative efforts and provides Archer with commercial opportunities to develop high-value graphene integration solutions in an emerging and growing graphene materials market.” Results of the technical analysis, performed at the world-class Australian Centre for Microscopy & Microanalysis at The University of Sydney and The University of New South Wales Mark Wainwright Analytical Centre, confirmed that the graphite from the Campoona deposit could be used to produce multiple graphene-based products from a number of different methods. This is critical for value-add applications and high-quality graphene production using graphitic feedstocks in the targeted areas of reliable energy, human health, and quantum technology. Graphene materials and technology are emerging with the potential to broadly impact existing markets that service the electronics and additive manufacturing industries. Graphene material sales and device integration are expected to form part of the market value potential of approximately US$70 billion by 2030.

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