Features

Manufacturers in just about every industry are already embracing the reality of Industry 4.0—that the digital transformation of factories is necessary, replacing manual processes with automated systems in cyber-physical smart factories. This is crucial to manufacturers as challenges caused by global disruptions can make it even more challenging for them to ramp up production to satisfy ever-volatile market demands.

There are many subtle differences in the obstacles faced by manufacturers in different industries, but there are also a few key challenges that all manufacturers have in common. Having a limited number of assembly lines makes it difficult for manufacturers to keep up with the rising demand for customised products as well as the accelerating rate of innovation (and by extension, obsolescence) in new products.

Many manufacturers still lack the visibility required to respond to supply and demand volatility in an agile manner. At the same time, it can be challenging to be mindful of the growing list of certifications required and regulations that manufacturers need to comply with—in addition to the growing pressure for manufacturers to shift towards more sustainable practices.

To be able to adopt digital transformation towards smart manufacturing, what manufacturers need is a solution where the virtual and real worlds converge in perfect synchronisation. With that in mind, manufacturers require real-time data from the real world, that can be used to model, plan, optimise and execute manufacturing operations with minimum risk. The team at 3DS DELMIA, part of the Dassault Systèmes Group, takes a closer look at just how effective virtual twins can be.

Optimising Operations Across the Value Chain

Virtual twin platforms come with a whole host of benefits and equip manufacturers with solutions for improvement at every stage in their value chain, allowing for better strategic and tactical decision-making. Listed below are some of the most pertinent:

• Facility Planning

Using anything from 2D drawings to fixed point scans of physical facilities, the 3D virtual twin allows manufacturers to plan assembly lines in a way that optimises the use of the available physical space. Perfect planning of assembly lines, workstations and tools through the virtual world minimises potential risks and avoids costly layout redesigns after the physical facilities have been installed.

• Process Planning

The Virtual Twin Experience can be used to plan the use of materials and resources in products, optimal processes for maximised production output, as well as safe work conditions. Virtual simulation of processes allows manufacturers to eliminate potential process or quality issues ahead of execution—reducing launch times and scrap while saving time and money from building manual prototypes.

• Manufacturing Planning

On a more tactical level, the Virtual Twin Experience equips manufacturers with the capabilities to adjust and optimise production while managing constraints in manufacturing, assembly and distribution. This can be applied to areas such as supply and demand planning or sales and operations planning through the use of forecast data—or help generate an optimised master production schedule.

• Manufacturing Execution

When it comes to manufacturing operations management, the virtual twins give manufacturers the agility and flexibility needed for tactical decision-making. Real-time visibility over all operations allows manufacturers to promptly carry out unplanned maintenance on machines or identify an urgent need to requisition materials—reducing downtime, eliminating silos and minimising risk.

• Raising Competitiveness Through Manufacturing Excellence

Companies have a prime opportunity to optimise and maximise returns in their manufacturing operations by leveraging the extensive capabilities of the virtual twins. By planning optimal processes and enhancing the cohesion between design, engineering and manufacturing, manufacturers can see a significant impact in:

• An increase in efficiency and operation rates
• Cost savings from elimination of physical prototypes
• Increased speed of NPI and time to market
• Sustainability in Manufacturing

At the business level, sustainability is becoming the most critical lever for strategy. It is shaping a new set of values that companies must embrace to ensure relevancy, conquer new markets, prepare their workforce for the future, and become part of the solution. Virtual twins are proven to provide manufacturers with a clearer vision of how key equipment can be run more sustainably – with many businesses already tapping into the potential that virtual twins provide.

There is no doubt that the world is moving towards a more sustainable future, and manufacturing must adjust to fit in line with this shift in thinking. Thankfully virtual twins provide business owners with a wealth of information that is geared towards not only sustainability but also longevity and operational excellence.

Innovation is at the heart of everything that manufacturers do, so there’s plenty of reason to get behind virtual twins and the multitude of benefits they offer to your business. From taking positive steps in reducing your business’ overall carbon footprint to guaranteeing each part of the manufacturing process is fully optimised, virtual twins can help.

Farnell, an Avnet Company and global distributor of electronic components, products and solutions, has launched the Boost Your Power campaign to provide a range of special offers and discounts on featured products from leading global test and measurement suppliers. Visitors to Farnell’s website can also download a range of free online power management resources and enter a competition to win an Apple iPad Pro, Amazon vouchers worth £250 and much more.

Test and measurement equipment supports the design process, allowing engineers to check their designs are performing as intended. Farnell is promoting a combination of the bestselling and new-to-market products to help engineers quickly and easily find test and measurement solutions to meet their power needs. Featured products showcased as part of Farnell’s Power Management Hub include:

• The QPX750SP Bench Power Supply by Aim TTi features a single adjustable output rated up to 80 V and up to 50 A. Front and rear terminals make it suitable for bench or system use, while high setting resolution and metering down to 1mV ensures accurate measurement and ripple. At <3mV rms at full power, the noise level is very low. In addition, an analogue control interface connection to LAN/LXI, USB, RS232† and GPIB on P versions is possible.
• The NGU401 Source Measure Unit from Rohde & Schwarz is perfect for challenging applications due to its extremely high accuracy and fast load recovery time. Data acquisition is performed rapidly with every detail detected down to 2 μs resolution. The NGU401 offers 4-quadrant architecture, 60 W output power and can function as both a source and sink to simulate batteries and loads. Customers are protected by a 3-year warranty as standard.

Farnell is also offering exclusive discounts and free product giveaways with selected test and measurement equipment, such as:

• 15% discount on the B&K Precision BK9833 Programmable AC Power Source: The low harmonic distortion meets the IEC 61000-3-2 standard and offers outputs of 300V/30A and 3000 VA, making it ideal for pre-compliance testing. A variety of power line disturbances can be simulated using pulse, step, and list modes using built-in or user-defined waveforms. Manual control is via numeric keypad, rotary knob, navigation keys, and a 4.3-inch colour LCD display which can display 12 measurements simultaneously. LAN, USB, GPIB and RS232 interfaces are built-in and control is possible from a standard web browser via integrated web server.
• Exclusive saver bundles from Tektronix and Keithley Instruments: Choose from either the Advanced Power Applications bundle or the IoT Applications bundle featuring oscilloscopes, probes, power supplies, digital multimeters, source measure unit, supporting software and more, available exclusively from Farnell.
• Keysight U1733C LCR meter for free with a purchase from a range of Keysight power products: The U1733C LCR device can operate at frequencies as high as 100 kHz and take fast measurements using the one-touch automatic identification function button which displays component type and more detailed analysis such as Z, ESR, and DCR. Customers can purchase selected Keysight products, including source measure units (SMUs), modular power systems, power analysers and power supplies, to access this offer.

In addition to the range of products on offer in the Boost Your Power campaign, customers can also enter the competition to win one of 20 prizes including an Apple iPad Pro, £250 Amazon gift card, discounts on selected Farnell test and measurement products and more.

The Power Management Hub provides extensive resources on featured test and measurement products, including oscilloscopes, probes, power analysers, bench power supplies, SMUs, DC loads and AC sources, as well as a selection of articles, brochures, guides, videos and on-demand webinars from Farnell’s supplier partners. Customers are invited to download a free exclusive article titled ‘Power Solutions in Test & Measurement’ to learn about the core pieces of equipment required for testing in research, product development, prototyping, production, and field-testing applications.

James McGregor, Global Head of Test and Tools at Farnell, said: “Power management plays a major role in virtually every piece of electronic equipment. We are proud to bring a vast array of products from leading suppliers to support our customers in their power management processes. By supporting them further with free-to-download technical content and a range of great discounts to reduce the cost of their purchase, they are fully enabled to overcome any challenge.”

Farnell offers a full range of market-leading test, tools and production supplies from stock to support electronic design and test, with no minimum order value and an educational discount programme. Customers have free access to online resources, data sheets, applications notes, videos and webinars with excellent customer and technical support available 24/5 in local language.

Customers can access featured products from market-leading suppliers including Tektronix, Keithley Instruments, Keysight Technologies, Rohde & Schwarz, Aim TTi, B&K Precision, Chauvin Arnoux, EA, GW Instek, Sefram and Sorensen. To find out more about how to Boost Your Power with Farnell, visit: uk.farnell.com/boost-your-power.

Powelectrics MetronView IIoT cloud now has over half a billion readings ….

Powelectrics’ well-proven, versatile MetronView platform has been actively developed since its launch over ten years ago. Highly scalable ….. all that lovely customer data is securely stored for future analysis.

MetronView collects data from a vast array of sensors, machines and IIoT devices. It gets Powelectrics’ customers’ data flowing … fast … from their first step towards digital transformation to the roll-out of an international estate of connected assets!

MetronView is a ‘universal’ IIoT platform, agile and responsive, collecting data from a vast array of sensors, machines and other devices, via a powerful suite of IIoT building blocks, which integrate GSM/GPRS, Sigfox, LoRa, LoRaWAN, RS232, RS485, Ethernet, Wi-Fi, CAN, MODBUS & IO-Link.

Generally used as a standalone cloud, with a known and transparent subscription model, MetronView provides current and historic data via customisable dashboards, sends alarms, remotely manages and controls devices in the field and performs mathematical and logical operations, such as anomaly detection.

Its intuitive features include:

• “CHART ANGEL”. A fantastic feature, which will allow data from several IOT devices to be placed together on one graph for easy identification of operational issues. Customers can now compare the performance of similar assets to identify anomalies.
• CONFIGURATION WIZARD. Remotely configure devices using a simple, intuitive wizard to define units of measure, sensor types and more and save configurations for future use. No need for training or programming skills.
• CONFIGURATION LIBRARY. To make life easy, customers can keep a library of regularly used configurations and simply select one for simple configuration … making it incredibly easy to manage devices in the field, whenever you like. Eg) Pre-set configurations for specific tank dimensions. No need for coding skills or technical support.
• HOVER FUNCTION. Hover anywhere over your graph for exact readings of all channels at a specific point in time.

An interoperable API allows data to be easily drawn into sector and application-specific platforms. 

You can view the MetronView Brochure here.

What can Powelectrics’ MetronView cloud do for you?

Please browse the Powelectrics website www.powelectrics.co.uk and get in touch with any queries about getting your sensor data into the MetronView cloud or applications you would like to discuss. Call the team on +44 1827 310 666, email sales@powelectrics.co.uk or use this contact form.

On November 3 and 4, industrial metrology supplier The Sempre Group will exhibit at Advanced Engineering at the NEC in Birmingham. On stand G80, The Sempre Group will showcase a range of metrology systems and software that enable manufacturers to realise Quality 4.0. Its experts will also be on-hand to consult on how integrating metrology throughout a production process enables manufacturers to improve productivity, reduce costs and remain competitive. Register to visit here.

On its stand, The Sempre Group will exhibit its comprehensive range of metrology systems and software from its broad supplier base. Visitors to the stand will be able to see how The Sempre Group can build bespoke automated metrology solutions, which will be demonstrated by collaborative robot working with a Micro-Vu multi-sensing CMM. The cobot can pick and place parts onto measurement equipment, and then sort them according to whether they are good or defective.

Attendees can find out more about the benefits of shaft measurement systems like the Opticline, which carry out fast and accurate measurements to help manufacturers ensure compliance. The Sempre Group will also showcase the Arkite Human Interface Mate, an optical projection system that guides operators with augmented reality (AR) instructions and the Gelsight 3D topography measurement system, a handheld tool that accurately measures surface roughness and defects.

In addition to equipment, The Sempre Group provides quality management software solutions that enable manufacturers to develop a centralised data system, simplify reporting and compliance and improve productivity. Visitors will see how High QA Inspection Manager automatically extracts geometric dimensioning and tolerancing (GD&T) data from a model, identifies critical dimensions and auto-populates reports and how Prolink enables manufacturers to make informed decisions by assessing collated data and reports.

“Our expert team will be at the event to listen to attendees’ concerns and determine the best way to solve each company’s unique metrology challenges,” explained Jim Mangan, managing director of The Sempre Group. “We are able to offer independent advice, drawing on our knowledge of equipment from a broad supplier base to design a bespoke solution that meets each customer’s business objectives.”

 To find out more about The Sempre Group’s automation services ahead of Advanced Engineering, visit www.TheSempreGroup.com/design-automation/. To register for Advanced Engineering, visit www.advancedengineeringuk.com.

Traceable reference measurement instruments used in accredited calibration laboratories, must meet the highest requirements in terms of precision, reliability, and quality.

To this effect, system specialist FORM + TEST relies on HBK’s dependable and high-precision measurement technology, in its ALPHA 2-5000 S compression testing machine, for the calibration of force sensors at a calibration laboratory in Singapore. 

The Singapore-based calibration institution required a special solution to carrying out calibrations for static compression force tests. FORM + TEST had the necessary expertise to provide the required highly precise special solution: its ALPHA 2-5000 S compression testing machine. 

The implemented measurement system guarantees precise calibration of force sensors, as well as continuous calibrations in the compressive direction. The system can also cope with the additional requirement of measuring very small force values The measurement solution can be used with a maximum precision of up to 1% of its maximum capacity. 

FORM + TEST trusted HBK’s measurement technology for implementing its compression testing machine, as HBK was the only supplier to guarantee the precision and reliability of its products and the entire measurement chain.  

The central element of the measurement system is a custom-built system, BU18, with three C18 ring torsion force transfer standards from HBK with a nominal force of 1.7 kN each. The capacity of the entire system is thus 5 MN. In addition, three type C15 reference force transducers, with a 5 kN, 100 kN and 500 kN measurement range, were integrated into the system for high-precision force measurement. These robust (EMC-tested, stainless-steel, shock and vibration-tested) shear force sensors with nominal measurement ranges between 2.5 kN and 1MN meet the requirements of accuracy class 00 according to DIN EN ISO 376 in the exceptionally broad measurement range of 10 to 100 % of the respective capacity. 

The DMP41 reference measuring amplifier completes the measurement system. With its unique accuracy class of 0.0005, the high-precision measuring instrument is the most accurate amplifier for strain-gauge-based measurements worldwide. As a result, HBK’s DMP41 was the first choice for implementing the ALPHA 2-5000 S. 

RS Components (RS) has announced availability of a complete series of circular connectors manufactured by CONEC Elektronische Bauelemente, part of the Amphenol Group.

Featuring 0.8mm diameter contact pins, the highly compact CONEC range of M8x1 D-coded circular connectors are fully optimised for industrial automation applications. These connectors present engineers with all the attributes necessary to meet the ISO11801 Class D standard for up to 100Mbit/s (Fast Ethernet) signal transmissions.

Suitable for a range of Ethernet-based communication applications including industrial interfaces and control and regulation units, as well as sensor, camera and robotics-based applications, the devices require only a small installation space. Key features of the connectors include variable mounting and connection options on the device side, power and data signal on one data pair, and continuous shielding.

Electrical characteristics include working voltages of 50V AC and 60V DC and a current rating of up to 4A at 40°C. Additionally, all the devices are protected against water ingress, rated to IP67.

The field attachable connectors include axial female and male connector variants and come with optional screw connections (female) or crimp connections (both female and male).

The Amphenol CONEC M8x1 series is shipping now from RS Components globally.

ABB has strengthened its existing digital offerings with the launch of ABB Ability Genix Asset Performance Management (APM) Suite for condition monitoring, predictive maintenance and 360-degree asset performance insights for the process, utility and transportation industries.

The Genix APM Suite makes it easy to add asset condition monitoring to existing operational technology (OT) landscapes, enables prioritisation of maintenance activities based on AI-informed predictions, and provides a comprehensive overview of asset performance.

Genix APM Suite also empowers significant improvements in operational sustainability. By assessing the remaining useful life of industrial assets, Genix APM generates a plan for preventive maintenance, which can extend equipment uptime by as much as 50 percent and increase asset life by up to 40 per cent.

With reliable data insights, decision makers are provided with the information required in order to identify gaps and areas of improvement for energy efficiency and tighter control of operations, increasing asset availability and improving profit potential.

“Poor asset availability and reliability is a major problem that results in unplanned downtime and unexpected maintenance costs, and also impedes strategic planning and procurement,” said Rajesh Ramachandran, Chief Digital Officer at ABB Process Automation. “It’s not that industrial customers lack data; it’s that many lack effective ways to use their data to improve operational and business performance.”

Genix APM is built on the ABB Ability Genix Industrial Analytics and AI Suite. ABB Ability Genix is a modular, IIoT and analytics suite, which integrates IT, OT and other enterprise data in a contextualised manner, applying advanced industrial AI capabilities that support new insights to optimise operations.

Automation is extensively used throughout automotive assembly operations to transfer components between multiple production lines. In this application, the workpiece is lifted from its original carrier and placed onto a new one where sensors on the roller conveyor check its position. Contrinex’s uniquely robust 700 Series inductive sensors, available from PLUS Automation, reliably ensure safety during the lift and transfer process as the assembly is moved.

Customer application

When the automotive assemblies arrive at the transfer station, the workpiece carrier holding them must first be halted. This is achieved with sensors on the roller conveyor which, when they detect the arrival of the workpiece carrier, cause the conveyor to stop. An industrial robot then lifts out the assembly and transfers it to a new workpiece carrier on an adjacent assembly line.

After checking that the assembly has been removed from the carrier, the roller conveyor must start-up and return the empty carrier to the workpiece loading station where automatic position checking is required to initiate the stop/restart of the roller conveyor. This prevents any product wastage or machine damage that could be caused by faulty manipulation of the robot.

Customer solution

The robust industrial construction and proven reliability, and the extended ‘Factor 1’ range of 15 to 40mm depending upon the 700 Series sensors diameter, equally on steel or aluminium make it the ideal inductive sensor for the application.

Just three DW-AS-713-M30 compact inductive proximity sensors were used to ensure the safe, reliable implementation of this task. These sensors are mounted between the rollers at the transfer station so that as soon as an incoming workpiece covers the second sensor, it is in the correct position and the conveyor can be stopped and actuators on the robot enabled.

Once the robot confirms the automotive assembly has been removed, the third sensor ensures that the empty carrier takes the correct onward path.

The switching distance accuracy of these sensors allows them to initiate a stop at exactly the right moment – neither sooner nor later. This, in turn, ensures the safest possible conditions are met as the lift and transfer process takes place while maintaining the speed and consistency expected from an automated factory process.

Contrinex sensors allow the roller conveyor to stop and restart at exactly the right moment for automated transfer stations and minimize wastage, downtime and damage to equipment.

Yokogawa subsidiary Yokogawa Solution Service Corporation along with Toyota Tsusho Corporation have received an order from Société Nationale Des Eaux Du Sénégal (National Water Company of Senegal) for the construction of a water supply management system. The work is to be undertaken as part of the Mamelles Sea Water Desalination Project, which is being financed by a loan from the Japan International Cooperation Agency. The construction of this water distribution network monitoring system will stabilize water supply and improve service throughout the Dakar Region. This is Yokogawa’s first order for a water supply management system in Senegal.

Around 80% of Senegal’s industrial activity takes place in Dakar, and the population of this city has been increasing in recent years. In addition to looking for ways to ensure a safe supply of water to this city, Senegal is working to diversify its water sources and reduce loss from water leakage.

The water supply management system to be constructed by Yokogawa Solution Service and Toyota Tsusho will improve access to the water pipe network and thereby ensure the supply of safe water to Dakar. Yokogawa Solution Service will install sensors to collect flowrate and pressure data at around 200 locations in Dakar’s water pipe network and construct a water supply management system that is capable of locating water leaks and other such problems. This will contribute toward the achievement of the project goals, which call for the achievement of at least a two million ton reduction in annual water losses caused by leaks in the water pipe network, and an increase in the 24-hour water supply rate from the current 70% to 100%.

To improve the supply of safe water in emerging and developing countries, Yokogawa Solution Service and Yokogawa Group companies will leverage the rich track record and wealth of water supply and wastewater treatment know-how that the company has gained in Japan.

Endress+Hauser and the Petroleum Extension (PETEX), a unit of the Cockrell School of Engineering at the University of Texas at Austin, announce collaboration efforts for training courses starting fall of 2021. PETEX will be hosting courses at Endress+Hauser’s Houston campus and will use the manufacturers’ PTU, the same PTU where Endress+Hauser’s authorised sales and service representative, Vector Controls & Automation Group, hosts Vector University classes for customers in the Gulf region.

“Along with our partner Vector Controls & Automation Group, we are excited to collaborate with such a prestigious organisation as PETEX and deliver a combined complementary basket of training classes to customers in the Gulf region,” said Jerry Spindler, Customer Training Manager, Endress+Hauser. “Our common goal of advancing the skills of the workforce in the Oil & Gas industry aligns well with the investments by both organisations in facilities and training equipment such as the PTU. Workers in the industry now have a world-class location where they can continue their technical education.”

The PTUs are full-scale, working process skids with functional instrumentation and controls, closely simulating a real-world environment. Trainees gain hands-on experience with the types of configurations, operation, diagnostics, and troubleshooting found in actual process plants and facilities. This specific PTU features working gas and liquid systems and is equipped with more than 200 modern Endress+Hauser devices, along with a variety of the latest instrument configurations, communication protocols, and software.

Roger T. Bonnecaze, Interim Dean of the Cockrell School of Engineering, noted, “For over 75 years PETEX has been providing talent development resources and courses for the global oil & gas sector. In Houston and Odessa, that has traditionally been at the PETEX training centres. With the significant investment that Endress+Hauser and Vector have made in the Houston facility to build one of their renowned PTU’s and create world-class classroom space, it made complete sense for PETEX to collaborate with them to bring those resources to our learners also. The PTU complements the hands-on programs already in place and allows us to collaboratively expand our offerings to continue to meet the ongoing training needs of the oil and gas sector while also embracing new technologies and energy transition topics.”