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MANUFACTURING & AUTOMATION magazine. This is latest edition of Automate Indonesia bring Robot News in Manufacturing Industry. In the cover story we coverage about ABB introducing YuMi (You and Me) the world’s truly
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collaborative dual-arm industry robot in Indonesia. we also provide you robot news come from Japan they have a revolution robot for workforce solution and the incredilble humanoid robot that sells out in 1 minute. Beside the robot news, we also provide for our ardent fans and readers out there the latest automation industry around the world to spur our manufacture industry in Indonesia. I would like to invite you to read our magazine regularly, send feedback, and share interesting articles that you may have us for us to improve the magazine. Automate Indonesia magazine is also available for download on our website www.automateindo.com for FREE. Thanks you for your support and cheer up
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ABB introducing robot YuMi (You and Me) in Indonesia COVER STORY The world’s first truly collaborative dual-arm industrial robot
MANUFACTURING & FACTORY AUTOMATION Rise Of the machines: robots poised to transform global manufacturing
INDUSTRY NEWS Some Considerations Need To Be Examined When Choosing Between Contact And NonContact Measurement Devices.
PROCESS AUTOMATION Refinery Pushes Asset Reliability
MACHINE WORLD DMG MORI with 7 world premieres at EMO
ROBOTS Japan humanoid robot sells out in 1 minute
How a grocery delivery service became a red hot robotics company
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RFID AND WIRELESS TECHNOLOGY The Role of RFID in the Smart factory
ELECTRIC AND POWER Singapore Power And EDB To Establish Centre Of Excellence
DID YOU KNOW? What Was The World’s First Robot?
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ABB introducing robot YuMi (You and Me) in Indonesia The world’s first truly collaborative dual-arm industrial robot In 2006, the world was at the very beginning of the smartphone revolution. At the time we could only imagine how this market would develop. Many envisioned a future which would bring exploding demand for affordable, miniaturized, mobile electronics.
“a new era in which human beings can have a robot partner has been present in Indonesia and this is one of the most important this part of ABB’s strategy next level said Richard Ledgard, Country Managing Director of ABB in Indonesia”
As humans while still ensuring the safety of those
around it. Few production arenas are changing as quickly as small parts assembly. The electronics industry, in particular, has seen demand skyrocket past the supply of skilled labor. As conventional assembly methods diminish in value, manufacturers are finding it strategically and economically imperative to invest ABB (www.abb.com) is a leader in power and automation technologies, today introducing YuMi into Indonesia Market, the world’s trully collaborative dual-arm industril robot that are able to work collaboratively on the same tasks with humans while still ensuring the safety of those around it. YuMi Present in Indonesia for the first time following the successfull launch of the robot YuMi at Hannover Messe trade fair on April 2015. Today, the market has turned into something beyond our wildest expectations. It is more complex than we ever imagined and requires an incomprehensibly vast system of manual assembly. Millions of workers, across thousands of assembly lines, build the electronics upon which the world has come to depend. The explosive growth and extremely short life cycles of these types of products, coupled with rising demand for more rewarding jobs, higher pay and better quality of life among workers, means that, ultimately, the current system is neither scalable nor sustainable. YuMi: Creating an automated future together With the introduction of YuMi, the world’s first truly collaborative dual-arm industrial robot, ABB Robotics is once again pushing the boundaries of what robotic automation will look like in the future and how it will fundamentally alter the types of industrial processes that can be automated with robots. A play on words, YuMi signifies “you” and “me” creating an automated future together. This groundbreaking solution is the result of years of research and development, heralding a new era of robotic coworkers that are able to work side-by-side on the same tasks.
in new solutions. While YuMi was specifically designed to meet the flexible and agile production needs required in the consumer electronics industry, it has equal application in any small parts assembly environment thanks to its dual arms, flexible hands, universal parts feeding system, camera-based part location, leadthrough programming, and state-of-the-art precise motion control.
At first glance, processes on manual assembly lines
might seem relatively simple to automate, but in reality it is not so easy to replicate human abilities—we are amazing machines. We have touch and motor control which allows us to handle delicate things with dexterity and precision, as well as judge how much force to use on a given component so that we do not break it. We can see where an item is, easily pick it up, and are able to handle an incredibly diverse variety of parts without pausing. We also have spatial awareness which allows us to interact closely and in harmony with our coworkers. With YuMi, the challenge was to determine how to replicate all of these human attributes in a way that was cost-effectiveessentially recreating the minimum number of senses and abilities necessary to be at least as safe as humans, yet still able to provide the substantial benefits of automation. Thr ough purpose-built design that is much more than just the robot, we have created an inherently safe system of components that delivers the precision, ease-of-use, speed, flexibility and r eturnoninvestment required for the future of small parts assembly. At its core, YuMi has the DNA of safety. Much like a human arm has a skeleton covered with muscles that provide padding, YuMi has a lightweight yet rigid magnesium skeleton covered with a floating plastic casing wrapped in soft padding.
This arrangement absorbs the force of any unexpected
This means that YuMi requires far fewer engineering
impacts to a very high degree. Like the human arm, YuMi has no
resources to accomplish very complicated tasks. Lead-Through
pinch points so that sensitive ancillary parts cannot be crushed
Programming can turn what used to be hours of tedious
between two opposing surfaces as the axes open and close. YuMi
programming into a few minutes of easy work. When the tasks
is compact, with dimensions similar to that of a human, and dual-
are more complicated than Lead-Through Programming allows,
arms featuring seven axes of movement each allow the robot to
full access to traditional coding using ABB’s RAPID programming
have greater dexterity and precision inside a compact, human-
language is still there when you need it.
sized workspace. YuMi only weighs 35 kg, hasm an integrated control system, integrated internal cabling for a mmultitude of input and output commands including air and digital, works off of standard household electrical power found the world over, and is extremely portable and re-deployable at will.
If YuMi senses an unexpected impact, such as a collision
with a coworker, it can pause its motion within milliseconds, and the motion can be restarted again as easily as pressing play on a remote control. When this is combined with the floating padding, safety for a human coworker is drastically increased. Even with these inherent safety features, YuMi is incredibly precise and fast, returning to the same point in space over and over again to within 0.02 mm accuracy and moving at a maximum velocity of 1,500 mm/sec. To handle the great variety of parts that are seen in today’s small parts assembly environments, YuMi comes with integrated and highly flexible hands which can be deployed in a variety of configurations, including servo grippers, dual suction cups, and vision. Altogether, YuMi’s hands allow for completem customization to meet the demands of most assembly tasks. However, the complex operational problems found in small parts assembly do not simply revolve around the flexibility of human hands; supplying the parts for a given task is also key to efficient operation. To address this we developed the Flex- Feeder™ system for parts delivery. The FlexFeeder stores a large number of parts, ranging from 3 mm to 30 mm in size, in a bin. Picking parts directly from the bin is a very complicated three-dimensional problem, so the FlexFeeder turns this into a much easier twodimensional picking operation by serving those parts from the bin in small numbers up onto a flat surface.
From this flat surface YuMi’s integrated hand cameras
can easily locate and then direct the grippers to pick parts. Finally, to make programming YuMi as simple as telling a human what to do, we have created a programming system so easy anyone can use it. In fact, we hesitate to even call it programming. It is more like teaching—and everyone intuitively knows how to teach. Simply guide YuMi’s arms and hands, using your own arms and hands, through a series of movements, logging waypoints and gripper actions on a paired tablet running the YuMi app. Watch as the software turns those movements into the underlying code that makes YuMi work—right in front of your eyes and in real-time. 7
Service-Related Industries To Get Robotics And Automation Boost The Singapore Industrial Automation Association and e2i ink a two-year Memorandum of Understanding to educate and train workers on robotics and automation. Companies here, especially those in the service-related industries, will soon get more help to adopt technology, after a new two-year Memorandum of Understanding (MoU) was signed between the Singapore Industrial Automation Association (SIAA) and e2i on Monday (Apr 6). Under the MoU, companies can expect events like knowledge sharing, visits and consultation for companies to learn about robotics and automation trends and applications, and more training for workers to know how to manage and use new technologies and applications. “Automation is widespread in manufacturing, and there is much potential for service-related industries to tap on the benefits of robotics and automation,” said e2i’s Chief Executive Officer Gilbert Tan. “Besides supporting companies to be more productive, we also need to prepare Singapore workers with new skills for growth areas,” he added. e2i is the Labour Movement’s career coaching and training arm. The e2i and SIAA hope to target 30 companies over the two years. The initiative was announced at the first Robotics and Automation Awareness Seminar organised by the e2i and SIAA on Monday. The event was attended by NTUC’s Deputy SecretaryGeneral Chan Chun Sing, and about 200 employers from servicerelated sectors. Making Workers Receptive to Change Mr Chan said that while companies are aware of how technologies can benefit their businesses, the problem lies in not knowing which one to adopt. 8
“Very often companies tell us it’s not that they don’t want to adopt the new technologies,” said Mr Chan. “But they need to know what are the new technologies that are available, and also what are the new ideas possible for their respective applications.” Companies are said to also face another challenge: Workers who are less receptive to change, or are fearful of getting replaced by the machines. One company, Decks, managed to work around that by having proper communication with and training its workers. The clothing retailer recently launched a radio-frequency identification (RFID) system, which faced initial resistance from its workers especially the older generation, despite them having to spend a substantial amount time typing out the delivery order (DO). “We did a lot of education, telling staff how this technology will help them” said Decks Managing Director Kelvyn Chee. “In the past, our staff used 5 to 6 hours to type the DO and the written note. Now, they just scan the things and the DO will be auto-generated. So I think they spend less than half an hour per day (now).” For companies, especially those in the service sector, to effectively adopt new technologies, Mr Chan added their customers will also need to be convinced they will not receive a lower quality of service with the use of such technologies.
“This is where the feedback of the workers is very important,” said Mr Chan. “Because they are doing the job day to day, they know what it entails. They know what are the areas that they need help in. And this is where conversation between the workers and employers is important, so that they can apply the appropriate technologies in context.”
Indonesia’s largest sugar technology and equipment exhibition!
IISC Indonesia International Sugar Conference 2016
An International Conference on the latest developoments in the Indonesian sugar industry
An International Exhibition of Sugar Companies, Sugar Technology & Its Supporting Industries
16-17 March 2016 Grand City Convex Surabaya, Indonesia BOO NO K W! www.sugarindo.com Major Highlights on the Indonesian Sugar Industry: • The Indonesia Government are preparing 3 key areas in the Eastern Indonesia for new sugarcane plantation • 21 potential, both native and non-native, investors are planning to open up new sugar factories • The trading system between Indonesia island specifically for white sugar will be simplified Co-Host By:
INDONESIA SUGAR TECHNOLOGY COMMUNITY
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PT Fireworks Indonesia
Some Considerations Need To Be Examined When Choosing Between Contact And Non-Contact Measurement Devices. By Eddy Lek, Product Marketing Manager (Asia Pacific), Faro Technologies.
Sources: www.iaasiaonline.com â€œIn the last few decades, the advent and rise of computer-aided technologies has significantly altered the way that companies approach industrial manufacturing. The entire process of design, manufacture, inspection, engineering, and analysis can now be done on the computer with different software tools using the same type of dataâ€? Manufacturers seeking to ensure consistency in product integrity and reliability place great importance on the inspection or quality assurance step of the production process. A possible means to an end is for companies to incorporate computer-aided coordinate measurement devices into their facilities. Having said that, the art of selecting the right type of device that suits the application is still a complex one. Broadly, typical considerations include measurement needs, accuracy levels, measuring speed, price, and device type. While there are several facets to the discussion, the greatest deliberation for most is arguably whether to pick a contact or non-contact method of measurement.
Deciding Between Contact & Non-Contact Measurement Systems
Contact and non-contact measurement devices have their inherent strengths, and the ultimate choice of either type would depend on the exact application, and the priorities that a company holds. Depending on what needs to be measured (eg: 10
size, material, and so on), as well as the type of application and the level of accuracy, precision, and speed required, metrology suppliers will then recommend the most suitable measurement solution to manufacturers. Given the level of investment involved, this decision is not typically approached with a trial-and-error mentality, nor is it usually self-prescribed. In fact, companies are often advised to make full use of comprehensive pre-sales consultations that metrology suppliers provide, so as to maximise the effectiveness of the product purchased. Portable 3D coordinate technology exists in several forms, including point-to-point contact instruments (eg: articulated arms and laser trackers), non-contact laser line scanners, and 3D imagers. Fundamentally, these devices provide the benefits of fixed Coordinate Measuring Machines (CMMs) with the added versatility of being portable, which allows the user to deploy wherever there is a need.
INDUSTRY NEWS In addition to being less cost-prohibitive than fixed CMMs, portable CMMs do not require a controlled environment, making it easier on the pockets to operate and maintain them.
Point-To-Point Contact Instruments
One of the most common portable CMM devices available is the articulated arm. Equipped with several articulating joints, these measurement arms are able to determine and record the location of a probe in 3D space and report the results through software. The name derives from the actual look of the hardware, resembling a human arm with a shoulder, elbow, forearm, and a wrist. To ascertain the position of a probe, the arms contain proprietary glass discs called encoders in each joint, and these encoders calculate the probeâ€™s position as the arm moves freely throughout its workspace. Typically, articulated arms come in models with either six or seven axes of rotation, providing the user with flexibility while performing measurements. The shorter the arm, the more accurate it will be as there is less mechanical error linked to the length of the sections. Apart from the articulated arm, another device that performs contact measurement is the laser tracker. Designed to handle larger working volumes, laser trackers offer extremely accurate measurements over long ranges. Put simply, a laser tracker establishes the precise location of a target in spherical space by measuring two angles and a distance, each time it takes a measurement. It does so by sending a laser beam to a retro-reflective target, which has to be held against the object being measured. The return beam reenters the laser tracker where the distance to the target can be determined using interferometry or phase shift analysis. The horizontal and vertical angles to the probe are determined using precision angular encoders attached to the mechanical axis of a gimballed beam steering mechanism. Using the two angle measurements and distance determined by the laser, the laser tracker reports the coordinate location of the probe to extremely high levels of accuracy. In addition, the laser tracker can follow or track the target as it moves in real time. This unique feature, coupled with the laser trackerâ€™s ability to internally sample points at a rate of up to 16,000 times per second, enables the user to digitise data on complex surfaces and measure the location of moving objects.
The device projects a laser line on the part to be inspected, which is reflected back towards the scanner and captured by a camera. Through standard triangulation methods, 3D locations are determined and recorded accordingly. By moving the laser line across the entire surface, the probe captures the 3D profile for further processing.
Designed as a portable solution, the 3D imager is a high performance, accurate, non-contact system, capable of capturing surface data of up to four million discrete points in mere seconds. The device uses light projection technology and a camera to generate true representations of any part placed in its field-of-view (around 0.5m x 0.375m). For larger parts, reference points can be added so that separate sets of point clouds can be stitched together when needed. Across Asia, contact measurement is still generally more prevalent in application as it is easier to perform point-topoint measurements. Laser scanning technology is excellent for acquiring quick and accurate measurements of many data points at once, which is especially useful for larger parts. These data points (also known as point cloud) require further processing, and this makes the process slightly more complicated, often requiring a longer training duration. The choice between contact and non-contact measurement depends on application suitability, and one is not necessarily always better than the other. Implementing noncontact measurement methods when they are not required might not be the most efficient or effective, as the technique would not be optimised for the customerâ€™s needs. Without a doubt, the trend is moving towards noncontact measurement methods as they provide more versatility. Combined systems are already available but there is still demand for standalone options, so it is likely that each type of measurement system will continue to thrive. That said, scanning technology for metrology purposes is advancing tremendously in terms of efficiency, precision, and accuracy. As technology improves, we expect more opportunities for non-contact measurement to open up, especially for applications like automated in-line inspection.
Non-Contact Laser Line Scanners As an option, laser line probes can be mounted to articulated arms to provide non-contact scanning capabilities. This technique is an suitable way to create a dense point cloud, which can be used for tasks such as inspection and reverse engineering. Suitable for delicate objects where touch probing should be avoided, non-contact scanning is a quick way to obtain a full surface model of a part. 11
A computerized maintenance management system is helping a packaging film supplier meet stringent food and beverage industry reporting requirements and further its continuous improvement. By Grant Gerke , Automation World Contributing Writer A recent predictive maintenance inspection identified six rollers and their bearings were in need of replacement. However, the bearings were not failing and this allowed Multifilm to check its inventory. “If we don’t have the supply, we can order it and we’ve caught it before the point of failure, which is the point of predictive maintenance,” Paetsch says.
Stringent tracking requirements from the U.S. Food and Drug Administration (FDA) of food contamination sources are affecting the supply chain all the way down to flexible packaging film manufacturers. Elgin, Ill.-based Multifilm Packaging recognizes the importance of the FDA’s regulations, and also the need for more continuous improvement goals. The company’s large, high-volume flexographic and extruding machines produce piece-wraps and high-barrier laminates for the snack, confectionary and food industries. Two production facilities typically run 24 hours a day, five days a week. Multifilm Packaging acquired Bigfoot computerized maintenance management system (CMMS) software from Smartware Group for the two plants to better leverage plant data for its predictive maintenance goals. “When we conduct scheduled predictive maintenance work orders, the time is almost cut in half [compared with unscheduled maintenance work],” says Dave Paetsch, plant engineer at Multifilm Packaging. “With scheduled maintenance work, our production staff can begin to shut the machine down and our staff can start performing maintenance before the machine completely shuts down.” The three main predictive maintenance inspections for the company’s large printing machines are infrared thermography of all electrical panels; ultrasonic bearing detection (on film rollers); and vibration testing of motors from Fluke. There’s also a fourth routine that includes basic, visual inspection by the production operators during normal print runs. Each of the predictive maintenance routines creates work orders that are electronically entered into the new CMMS and scheduled at weekly maintenance meetings.
The CMMS is a standalone online system that Multifilm’s staff was able to integrate with internal resources. The company started with its basic equipment, entered its predictive maintenance history, and trained plant floor operators. “Once the CMMS was up and running, then we added the parts express module,” Paetsch says. “This is where we actually inventory our parts and assign cost of parts to specific work orders that are assigned to a specific machine on the plant floor.” Multifilm’s CMMS maintains inventory and provides low inventory alerts of critical replacement parts, and also Paetsch is able to track the cost of parts for a machine on a real-time basis via barcode data entry. The company characterizes its work order system as a hybrid between digital and print orders, due to food industry traceability demands. Paetsch signs off on all completed work orders, which has to be an actual physical piece of paper—but the new CMMS allows Multifilm to consolidate this process. A spreadsheet contains all work orders each morning and is printed via the CMMS. At the end of the day, operators fill out individual work order sheets and these sheets describe what was done for a particular work order number, assigned machine and how long it took. Paetsch uses the CMMS to track technician labor and add it to the cost of maintaining equipment, along with total labor hours. The company also tracks downtime, whether lost production or non-production downtime. Management tracks predictive maintenance work orders per month and production lost due to maintenance. Last month, the flexible packaging printer had 60+ predictive maintenance work orders. Of those, 15 unscheduled work orders accounted for almost half (48 percent) of the time required for maintenance that month. “I just started tracking that recently, and it proves the point of unscheduled always costing you more time,” Paetsch says. “Our goal is to reach 90 percent scheduled preventive maintenance work orders and 10 percent non-scheduled
Robots are serving customers in Japanese department stores and banks, as well as building advanced machines for the nation’s manufacturers. Has the future already arrived in Japan, or is the “robot revolution” sought by Prime Minister Shinzo Abe an impossible dream? Opening Japan’s official Robot Revolution Initiative Council on May 15, Abe called on the nation’s corporate sector to “spread the use of robotics from large-scale factories to every corner of our economy and society.” Backed by 200 companies and universities and chaired by Mitsubishi Electric’s Tamotsu Nomakuchi, the council aims to expand robotics throughout Japanese industry, with a goal of growing sales from 600 billion yen ($4.9 billion) a year to 2.4 trillion yen by 2020. According to the council, robot technologies “possess the potential for solving social challenges, such as resolving labor shortages, releasing people from overwork, and improving productivity in a variety of sectors, ranging from production in the manufacturing industry, to medical services and nursing care, and to agriculture, construction and infrastructure maintenance.” Japan’s robot revolution is evident at such places as Mitsukoshi department store in central Tokyo, where a kimonoclad greeter, “Aiko Chihira” made by Toshiba welcomes visitors. Mitsubishi Tokyo UFJ recently unveiled a robot assistant to provide basic customer service, while the PARO baby seal robot has been deployed in nursing homes overseas to support dementia patients. But beyond the cute and fluffy, Japanese companies have long been world leaders in factory robots, led by such businesses as Fanuc, Kawasaki Heavy Industries and Yaskawa 14
Electric. According to Japan’s Ministry of Economy, Trade and Industry (METI), the nation is the world’s top supplier of industrial robots, earning sales of 340 billion yen in 2012 and accounting for around half the market, as well as having a 90 percent market share in key robotics elements such as precision reduction gears and force sensors. Yet despite its market-leading position, METI has highlighted the risk that Japan’s robotics industry, like other domestic industries, becomes another “Galapagos” where “craftsmanship enjoys a victory but business suffers a defeat.” METI notes a growing international challenge, including the U.S. government’s multi-million dollar “National Robotics Initiative” and moves by companies such as Google to investing in driverless cars and other technologies. Europe is also seeking to catch up, launching last year its “EU SPARC Project” aimed at fostering private-public collaboration. Yet the bigger competitive threat may come from China, which according to METI is already employing more robots than Japan, with some 37,000 in operation as of 2013. Beijing is targeting domestic sales of industrial robots of 3 trillion yuan ($500 billion) by 2020, a tenfold rise on the current level.
INDUSTRY NEWS Elsewhere in Asia, South Korea has doubled robot sales since 2009 to reach 2.1 trillion won ($1.8 billion) in 2012, with the government targeting 7 trillion won worth by 2018. “Robot Land,” a $660 million government-subsidized theme park, is due to open next year, while Seoul is also investing 1.1 trillion won to help promote its robotics industry, currently ranked fourth worldwide in deployment of industrial robots.
Jobs Fix or Threat? Japan sees robots as a potential solution to its rapidly aging society, with the number of citizens aged 65 and above hitting a record-high 32 million in October 2013, a quarter of the populace, with social security costs also reaching a record high of 108 trillion yen in fiscal 2012. With Japan’s workforce now below 80 million and forecast to decline further, robots are seen as a potential solution along with increased female workforce participation, with mass immigration viewed as politically unfeasible. Unemployment is currently at an 18-year low of 3.3 percent, and with unfilled jobs at a two-decade high, manufacturers like food maker Ajinomoto are reportedly increasingly mechanizing production due to their inability to find staff. “Shortage of labor is a structural problem Japan faces in the long run, given the aging society,” Kyuuichiro Sano, director of a METI division in charge of state-of-the-art technology, told Reuters. Japan’s confidence in robots contrasts with alarmist reports in Western media about the potential threat to jobs. According to Australian research, nearly half of all current jobs could be automated by 2020, with even traditional white-collar jobs such as accountants, bank tellers and secretaries reportedly at risk of elimination. However, the Australian Industry Report 2014 also pointed to the benefit of increased productivity, with eventually cheaper goods and increased disposable incomes. The effect is akin to the Industrial Revolution, “when the invention of the loom led to waves of unemployed weavers, but cheaper clothing for the masses,” Australian government economist Mark Cully told BRW. Tokyo-based management consultant Lem Fugitt, publisher of website “Robots Dreams,” says Japan’s robot revolution will happen, although not perhaps in the form envisaged by the government. “The government can be a cheerleader, but it doesn’t have a lot of direct control over the robotics industry and its investments. There’s been a lot of academic investments like Cyberdyne’s exo-skeletons to help the elderly, and PARO the robot seal, but while they get great publicity, they haven’t even come close to developing a sustainable business model,” he told Pacific Money. “On the other hand, you have companies driving their own initiatives like Toyota and Honda, and these are sustainable the government 2020 initiatives are based around the Olympics, and I’m skeptical about how committed Japanese companies are to achieving them.”
Asked about the main threat to Japan’s leadership in robotics, Fugitt said: “China far and away; they have a big enough internal market that they don’t need to export…South Korea could be a threat if the chaebol opened up and shared technologies but I don’t see it happening. The U.S. will come in and disrupt things, they’ll cause chaos in a particular market and then run away.” Fugitt said Japan’s weakness was in application and deployment of its advanced technologies. “The Japanese expect other countries and people to appreciate their technology, but they’re inwardly focused. If it doesn’t make sense to them, they typically don’t do it,” he said, citing the example of Japanese advanced wheelchairs having 100 kilogram weight limits. Yet the future lies in more automation as opposed to more robots, according to Fugitt: “I don’t think we’ll see more robots in department stores replacing customer service – it’s more about self-checkout counters, and this kind of automation is already transforming the way things are done here. “Robots are a red herring in this debate – people are not threatened by robots, but by society and management decisions. For example, we already have the technology for driverless cars, which have had very few accidents, and when they have it’s been the fault of the human driver. But the biggest resistance is that people want control – we could have a totally automated transportation system tomorrow, if it wasn’t for social pushback. For Japan, deploying intelligent machines and increasing automation could deliver an enormous economic boost. According to Boston Consulting Group, Japan’s robots could help slash 25 percent off factory labor costs by 2025, while big gains could result from improving productivity in the service sector, estimated at only 60 percent as productive as the U.S. level.
Source: the diplomat 15
MANUFACTURING & FACTORY AUTOMATION
Rise Of the machines: robots poised to transform global manufacturing Advanced industrial robotics are at an “inflection point,” with lower costs and higher capabilities set to reshape the global manufacturing industry, according to new research from Boston Consulting Group. It predicts that, in the next decade, almost a quarter of automated tasks will be performed by robots – up from 10 per cent today.
The pace of adoption will be particularly quick in Canada, due to relatively high labour costs, flexible laws and because much of the manufacturing base is in transportation: the sector most likely to deploy robotics. A rapid pickup in usage will improve cost competitiveness relative to the United States, the report says. 16
Price is seen as the key driver of a “tipping point” in robot use. While prices have fallen in recent years – a new red robot called Baxter, for example, who costs less than $30,000, can package bottles – costs are expected to drop 20 per cent, while performance – in speed, flexibility and “other attributes” – will rise 5 per
MANUFACTURING & FACTORY AUTOMATION
Of course, the rise of the machine will reduce the need for human labour, causing longer-term implications for employment. In Canada, the manufacturing sector employs nearly 1.5 million people, according to Statistics Canada’s payrolls survey, making it the third-largest sector by number of workers in the country. “There will be less people working in the factories. On the other hand, there’s going to be a much higher-paid work force in the factories and more skills training,” Mr. Sirkin said.
cent a year in the next decade. “We’re at a tipping point in terms of the costs of human labour versus the cost of robotic labour, with human labour getting more expensive in most countries and robotic labour getting cheaper and cheaper,” said Hal Sirkin, Chicago-based senior partner. For example, he cites a U.S. spot welding machine that works for about $8 an hour as opposed to a human welder who costs $20 an hour for the same output. Robots are already transforming the factory floor, and the pace of change is expected to accelerate as robotics become easier and safer to use. Growth in the rate of industrial installation is seen hitting 10 per cent a year from about 3 per cent a year currently as the economics of robotics “get more favourable,” he said.
Canada’s manufacturing cost competitiveness is projected to improve by two percentage points relative to the United States by 2025 due to labour-cost reduction and productivity gains from robotics, the study says. In the near term for Canada, a sinking currency means imports of machinery and technology have become more expensive. But the loonie’s fall also makes this country’s exports more competitive – suggesting some opportunities for robotics makers. The potential market for advanced industrial robotics is estimated at about 14 million units last year, with growth expected at about 2 to 3 per cent per year. The study figures the U.S. will deploy 1.2 million robots in the next decade.
The study, to be released Tuesday, predicts robots will boost productivity by up to 30 per cent in many industries over the next decade and cut labour costs by 16 per cent or more. The transition to robotics is seen being driven by four industries: Computer, electrical, transportation (including autos and equipment) and machinery sectors will buy about three quarters of robots through to 2025. “The era of moving factories to capitalize on lowcost labour is coming to an end,” the study says. Rather, production lines will become more customized, factories will become smaller and more localized, and there will be fewer barriers for small and mid-sized companies. The work force, meanwhile, will require different skills – such as programming or mechanical engineering. 17
Engineers and executives at the MOL Danube Refinery in Hungary made a conscious decision to not only hook up smart instruments, but to get the full use out of the data they could provide.
Seven years ago, 93 percent of Europe’s oil refineries
were generating a profit. And then the bottom fell out. “After
use of HART devices. The refinery had made the decision to install HART-enabled intelligent field instruments as part of a
the economic crisis, the situation changed significantly. Profits
maintenance strategy to increase operational reliability.
dropped and melted,” said Gábor Bereznai, director of control and electrical engineering at the MOL Danube Refinery in
Százhalombatta, Hungary, near Budapest. “In 2009, loss-
are HART-enabled; other instruments include 8,000 pneumatic
Today, some 30,000 analog instruments at the refinery
generating companies reached 35 percent.”
devices (standard 4-20 mA) and 2,000 Foundation Fieldbus devices. About 3,000 of the HART devices are connected
And those assets are considerable. Though relatively
directly into a computerized maintenance management system
small on a list of major global players, the Danube location is
(CMMS), including an online field instrumentation maintenance
an important refinery for Central Europe. It processes crude and
alternative crude oils from the Friendship and Adria pipelines, and is the leading producer of clean fuels for the Hungarian market, producing diesel and gasoline blended with bio components. MOL has 58 process units at the Danube refinery, 95 percent of which are equipped with distributed control systems (DCSs) and safety PLCs. Many of the critical units are on serial connections, so if one breaks down, they all stop, Bereznai said, making reliability that much more critical. The MOL Danube Refinery received the HART Plant of the Year Award in 2010 for its demonstrated creativity in the 18
The difference in how the refinery does maintenance has been considerable. Since integrating the asset management system with the DCS and CMMS, Danube has seen a significant impact on unplanned downtime, on units both with and without FIMS, though units with FIMS. “Where we have a diagnostic system, the unplanned downtime is much less than where we didn’t have a diagnostic system,” Bereznai noted. They can save $350,000/year with online FIMS. Return on investment is reached in just three years, he added We started with a small pilot unit, and everybody was invited to see the results. Step by step, we spread this
PROCESS AUTOMATION technology around the entire refinery. As one audience member noted, it’s all too typical for plants to use HART-enabled instruments without making use of the available HART data. Bereznai agreed that it is common for operations to do little more with the data than to support calibrations. But the MOL Danube Refinery made the decision more than 10 years ago, Bereznai said, to really make use of the HART functionality in the instruments. “We find the system can give us more,” he said. “We started to deal with the integration. It was a tough job, but after some months, it was a success.”
There were important factors to make the project
a success, Bereznai said, including strict standardization, committed leadership support, a common way of thinking among field staff, support from unit leaders, and treating the system as a living, continuously developing entity.
They started small, and took it step by step, Bereznai
emphasized. “We started with a small pilot unit, and everybody was invited to see the results,” he sais. “The unit leader was very happy with the results. Step by step, we spread this technology around the entire refinery.”
The MOL Danube Refinery still has more plans to
expand capabilities. “We want to spread this solution to another
Bereznai, speaking to attendees of The Automation Conference last month in Chicago, was explaining how in an environment where refineries were fighting for profit, it became important to pay closer attention to asset reliability and availability”
six units. We want to infiltrate it into all the projects—all the brownfield projects, all the greenfield projects,” Bereznai said. “We have taken some steps to integrate ERP with this system, but we know this is the future.”
SYSMAC Traceability Solution
Reading of Direct Part Marking (DPM) with code verification and recording to DB directly via
Utilizing One Software tool - SYSMAC Studio
FH Series Vision System NJ Series Controller
Data is written directly into the DB w/o need for PC (gateway)
Images storaged Directly to DB
Part ID Code Read before assembly
Consumer demand is driving automakers to continuously produce safer and more efficient products. As a result of this automakers are constantly striving to achieve a target of zero defective parts in every batch produced. This goal can only be achieved by putting in place a system capable of total traceability, a system capable of back tracing every step of the manufacturing process, specifically the quality assurance and specification data.
Data set of different variables (Image + Data) can be captured and store as one data set
Serialization of all blister pack within each box
Final Assembly Inspection
Capturing Batch and expiry info
Readability of 1D Code of packaging
Currently, computers are key for transferring data from the manufacturing site to the main server. This requires a major investment of time, effort and resources to implement as they need to integrate various quality inspection devices such as Vision, Profile and Measurement Sensorâ€™s data as well as RFID information. For this, they need an IT specialist to work on the required software and an instrumentation specialist to oversee the necessary equipment. The biggest challenge is not just the in-depth understanding required for integration and maintenance, but also the cooperation needed between the two departments. Other elements which must be considered are software upgrades, antivirus and developments in hardware.
Data is written directly into the DB w/o need for PC (gateway)
NJ Series Controller
FH Series Vision System
With the Omron SYSMAC platform, we offer seamless integration with your main server without needing to worry about the various points of integration with computers. SYSMAC can enable the easy integration, control of Vision and Smart Measuring Sensors along with Temperature Controllers, RFID code readers and 3rd-party devices such as Nut Runners. All of this results in easier and lower maintenance which can be done remotely, ultimately reducing the Total Cost of Ownership (TCO).
Preview EMO 2015, Milan DMG MORI with 7 world premieres at EMO
DMG MORI will be confirming its status as a world market leader in the field of metal-cutting machine tools with 7 world premieres as well as a representative cross-section of its high-tech portfolio at the EMO in Milan. modernised and extended last year, DMG MORI will be setting new standards in the manufacture of machine tools. A new 1,200 m2 assembly hall has been created – accompanied by a 1,000 m2 technology centre, in which customized solutions and innovative high-tech machines are developed and can be presented to customers under production conditions. The EMO world premiere SPRINT 32|5 and its upgrade SPRINT 32|8 are “made in Italy” as well as the universal turning machines NLX 2500SY|700 and CTX alpha 500. The turning & milling machining centre CTX beta 1250 TC, the production turning machine SPRINT 50 and the automatic multi-spindle machine GMC 20 ISM are other EMO exhibits made in Italy.
SPRINT 32|5 and SPRINT 32|8 – Extension of the successful SPRINT series for parts with diametres of up to 32 mm A18S_Wasino
The EMO in Milan will provide DMG MORI with the perfect showcase for new advanced technologies and innovative products. From 5 to 10 October 2015, the technology partner will be presenting a total of 7 world premieres at its stand in Hall 4. In the field of turning technology, there are 4 world firsts: the production turning machine SPRINT 32|5 (including the equally new extension stage to SPRINT 32|8) built in Italy, the second generation of the turning & milling machines CTX gamma TC in two sizes and the NLX 6000|2000 turning/milling centre for large components. The three milling innovations all originate this time from the 4th generation of the duoBLOCK® series. Other highlights of DMG MORI’s trade fair presentation are the introduction of the automatic lathes from DMG MORI WASINO that have been strengthening the DMG MORI product range since 1 April 2015. Thanks to two Italian production sites, the EMO in Milan will be something of a home match for DMG MORI. Since 1969, GILDEMEISTER Italiana S.p.A. from Bergamo has been synonymous with high performance lathe technology and within the Group has a special focus on production and automatic lathe machines. Now that its site has been 22
The SPRINT 32|5 is designed for both short and long turning of workpieces of up to ø 32 x 600 mm. With a base area of less than 2.8 m², the new development is an extremely compact production facility. The SPRINT 32|5 machines materials in rod form up to 32 mm in diameter using two spindles and a 2-channel controller. DMG MORI keeps part costs to a minimum in this way. 22 tools on two independent workpiece carriers also make it possible to carry out complex machining processes. The automatic lathe also machines demanding workpieces radially at the main spindle with four driven tools. In total, the machine is equipped with five linear axes and on C-axis for the main spindle. Other options are the unloading device for workpieces up to 600 mm in length, and the high-pressure coolant supply with 120 bar. As an upgrade, DMG MORI is presenting the SPRINT 32|8 at EMO as another extension of the SPRINT range. The SPRINT 32|8 is equipped with 3 independent linear carriers for 4-axis machining on the main spindle and offers space for up to 28 tools. The machine has six linear axes in total including a second Y-axis. Two C-axes are available as well – one for the main spindle, one for the counter spindle. In addition to the attainable pluses in performance and flexibility in relation to complex components, the ergonomic operation and the durable construction underline the performance of this innovation.
MACHINE WORLD CTX gamma TC 2nd Generation – Complete machining with the new compact MASTER® turning/milling spindle
NLX 6000|2000 – powerful turn & mill machining with torque of up to 12,000 Nm, long parts and large diametres
Better performance and a bigger working area are the main features of the new CTX gamma 1250 TC and CTX gamma 2000 TC. The indisputable highlight of the two 2nd generation machines from DMG MORI is the ultra-compact turning/milling spindle. Their compact dimensions translate into a space saving of 70 mm, meaning that 550 mm long workpieces can be horizontally drilled out or hollow turned. The elevation in the X-axis has been increased by 150 mm, thus extending the options for the machining of large workpiece diameters. In addition, the Y-axis now offers 20 mm more travel. The maximum turning length is 1,300 mm in the case of the CTX gamma 1250 TC. The big sister model has a turning length of 2,050 mm. The turning diameter is 700 mm, respectively.
In its development of the compactMASTER® turn & mill spindle, DMG MORI has increased the turning torque by 130 percent, meaning that up to 230 Nm is available to users. The spindle operates at speeds of up to 12,000 rpm. The new CTX gamma TC models also have improved dynamics: The feed speeds of 50 m/min in the X, Y and Z directions have been increased by up to 65 percent. With the optional linear drive in the Z-axis, the turning/milling machines achieve up to 60 m/min in fast feed and an acceleration of 1g. Equipped with a B-axis and the technology cycle, the two world premieres are ideal for 5-axis simultaneous machining. For 4-axis production turning, a bottom revolver is optionally available as the 2nd tool carrier. This can accommodate up to 12 power tools at up to 10,000 rpm.
The highlight of the NLX 6000|2000 is the applicationoriented selection of powerful spindles. The range starts at type B with a spindle diameter of 185 mm. In this case, the maximum speed is 1600 rpm, and the torque is up to 7,000 Nm. The range of spindles is rounded off by two spindles, each with impressive torques of up to 12,000 Nm. Type C has a diameter of 285 mm, and for the type D it is an impressive 375 mm.
duoBLOCK® 4th generation – Strong and precise: new duoBLOCK® machining centres of the 4th generation
The latest generation of duoBLOCK® machining centres excels with its unique rigidity and extremely high precision. Above all, the sophisticated cooling system with comprehensive cooling features on the spindle head, NC round table and in the basic machine guarantees long-term precision even in the standard version. The large modules of the duoBLOCK® series also contain numerous options for machine customization such as the precision package, which includes cooling of the entire feed drive or bed temperature control. Furthermore, the customer can select from the widest range of spindles currently on the market – with torques up to 1600 Nm. In combination with the optional heavy duty machining packages, users get up to 50 percent better milling performance in titanium and Inconel. The world premieres in the duoBLOCK® model series include the DMC 100 U duoBLOCK® universal milling machine and the DMC 100 H duoBLOCK® and DMC 125 H duoBLOCK® horizontal centres. The distance from the spindle to the centre of the table of the two horizontal machining centres has been increased by 200 mm, meaning that now sufficient room is available for long tools up to 900 mm.
With more than 2,300 installed machines, the SL series from DMG MORI has written an impressive success story over the last years. The NLX 6000|2000 now opens a new chapter setting new standards in the powerful turn & mill machining of workpieces up to 2,000 mm in length with a diameter of 920 mm – with a chuck diameter of 600 mm. The basis for productive and high-precision machining on the NLX 6000|2000 are the tremendous rigidity of the drive trains, the structure of the machine bed and the flat guides with their high damping characteristics. The outstanding milling performance is guaranteed by the revolver magazine with BMT® technology. The integrated direct drive motor achieves up to 4,000 rpm and a high torque of up to 117 Nm.
DMG MORI WASINO – Ultra precise production lathes with 0.2 µm roundness precision for production lines in the automotive industry
WASINO, a brand belonging to AMADA MACHINE TOOLS CO., LTD, has more than 75 years of experience and develops and builds high-precision production lathes for the automotive, optical and other industries. Now that DMG MORI has taken over the lathe portfolio of AMADA, the models are now also being integrated in the global sales and service network of the machine tool manufacturer. The product range includes the G series, the J series and the A series of which DMG MORI will present two representative models during the EMO. The robust design and low centre of gravity of the WASINO models of the G series make them particularly suitable for applications in which a high degree of mechanical and thermal stability is required. In combination with the linear tool carrier, the G series is thus predestined for use in finishing including for ultraprecision applications. The J-series provides a selection of high-precision and extremely compact automatic revolver lathes that are designed for quality-oriented preparation and finishing of small precision workpieces. The models of the WASINO A series from provide users with the largest number of tool locations, and in the case of the AD-18S a counter-spindle for demanding 6-side
complete machining. The focus of these machines is highprecision machining of complex turn & mill parts. Therefor the machines are equipped with a Y-axis and space for driven tool. The A-18S, for instance, can be set up with 18 (driven) tools. Additionally, with the GG-05, the JJ-1, and the AA-1 the WASINO portfolio offers in each of the three series a two spindle lathe for the highly productive serial production.
ECOLINE New Design â€“ Optimised ergonomics and greater stability
machine tool manufacturerâ€˜s entry-level segment. Significantly more robust and scratch-resistant finishes made from anodised aluminium and powder-coated metal cladding provide a high degree of value stability. DMG MORI has also designed the ECOLINE models to be even more ergonomic with regard to accessibility. The safety windows of the machines can be quickly and easily replaced from the outside. The universal turning machine ecoTurn 450 has furthermore internal chip protection that prevents damage to the window.
The latest design evolution of the ECOLINE model series from DMG MORI underlines the high quality claim of the
Innovation Project “Machine Tool 4.0”
“MachineTool 4.0”as a milestone on the road to digital transformation
have it delivered within the shortest possible time. So much to the vision. The status quo, of course, looks very different. Not even basic and more importantly globally coordinated rules and standards are in place yet. But DMG MORI and Schaeffler Technologies were no longer willing to wait. With their innovation project “Machine Tool 4.0” they have together developed an intelligent machine – namely the DMC 80 FD duoBLOCK® turn/mill centre. An example of this future-orientated “Machine Tool 4.0” will be on show at the DMG MORI stand in Milan. The second prototype will then already be up and running and in everyday use for series production in the Schaeffler Höchstadt plant and from there will enhance the EMO presentation with status data from the shopfloor. Successful interplay of information technology
At The EMO 2015 in Milan, DMG MORI and Schaeffler Technologies will be presenting the innovation project “Machine Tool 4.0” as a milestone on the road to future-orientated production, process and maintenance optimisation at the EMO in Milan. Calculable availability of means of production ranks as a decisive factor in the realisation of cyber-physical production networks. This has led to the optimisation of service and maintenance processes progressively moving away from the back burner and into the limelight. That is why DMG MORI has collaborated with Schaeffler Technologie to start the innovation project “Machine Tool 4.0” taking the mill/turn centre DMC 80 FD duoBLOCK® as a specific example. To achieve their aims more than 60 sensors have been installed on elementary components of the FD machine. Together with other (obligatory) status information, all data are now captured in realtime and analysed using specially developed algorithms. As a result, the evaluation of the data provides qualified insights into the probable occurrence of different process and production faults. This in turn enables users to take targeted measures in advance for the first time, where currently unplanned machine downtimes quickly render capacity planning a waste of time. The extent to which the above-mentioned theory is actually implemented in day-to-day machining routine could be experienced live by visitors to the DMG MORI stand at the EMO in Milan. Energy and running costs have also been reduced significantly in addition to the increase in availability and simultaneous reduction of service costs. This new “knowledge” also constitutes the basis for the sustainable optimisation of processes, products and machines.
Both machines have an identical integral Industry 4.0 concept, from the sensor to the cloud, that connects existing technology with the new possibilities of digitalization and data analysis and thus masters the close interplay of mechanics, electronics and information technology. Comprehensively equipped with intelligent sensors, operating status and process data are collected here continuously in realtime and saved and
Picture 1 A Although not visible from the outside, the two DMC 80 FD duoBLOCK® machines of the innovation project “machine tool 4.0” are nevertheless packed full with intelligent sensors as the basis of condition-oriented service and maintenance. To achieve this more than 60 sensors have been installed on elementary components of the FD machine.
Future-orientated joint project “Industry 4.0“ is the hot topic of the moment. The fundamental ambition of the 4th industrial revolution is the individualised manufacture of products in digitalized, decentralised, self-controlling cyber-physical production systems. On this basis every customer is to be offered his/her product customised to the conditions of mass production and
Picture 1 B Comprehensively equipped with intelligent sensors, operating status and process data are collected continuously for the DMC 80 FD duoBLOCK® in realtime and saved, processed and analysed both locally on the machine in CELOS® as well as in the cloud. 25
MACHINE WORLD processed both locally on the machine in CELOS® as well as in the cloud. In addition, the collected data are analysed in the cloud using specially developed algorithms in order to detect potential faults or problems in the process by means of qualified forecasts. This status information is then fed back to the machine. DMG MORI has developed a special CELOS® APP – the “Condition Analyzer” – that functions as the information centre on the ERGOline® control with CELOS® and via which all status information is visualised and from where the operator can immediately initiate any actions that might be necessary. A small factory of the future within the factory of today “The DMC 80 FD duoBLOCK® is an absolutely highend product“, explains Alfred Geißler as the Managing Director of DECKEL MAHO Pfronten GmbH, which is responsible at DMG MORI for the innovation project “Machine Tool 4.0”. And he goes on to stress: “With its pallet changer, numerous tools and complex capabilities of up to 5-axis simultaneous milling in combination with sophisticated turning processes the machine is perfect for giving a representative documentation of the utilizable value of sensor-integrated intelligence.” Gained in practice, for use in practice Seen from a practical point of view this applies to an even greater extent to a second machine already installed in the Schaeffler plant in Höchstadt, as the manager of the business division production machines at Schaeffler Technologies, Martin Schreiber explains: “With our products we are both a system partner of international machine tool construction as well as a user of machine tools. So with our investment in a new DMC 80 FD duoBLOCK® we have combined what is necessary with future-orientated developments, in that we as a user can now gain important experience with an intelligent machine directly from the factory environment and then as a system supplier pass on this plus in competence to our customers and partners.” Enabling customer benefit to be experienced “The presentation of customer benefit is the focus of the innovation project”, stresses Alfred Geißler: “With the “Machine Tool 4.0” we demonstrate what can already be implemented today, enable the possibilities of Industry 4.0 to be actually experienced and show ways in which companies can master entry into the digitalized world of production on their own.” Intelligence as a standard The fact that even as a “Machine Tool 4.0” the DMC 80 FD duoBLOCK® still remains in principle a normal high-tech standard machine from the DMG MORI portfolio is bound to build confidence among users. Alfred Geißler: “The entire control and operation is not different from that of a standard turn/mill centre. This applies in particular to the CELOS® user interface as a centre of communication and organisation.” The only new elements are the machine’s internal network to which all additional sensors, actuators and evaluation units are connected and the CELOS® APP “Condition Analyzer” as an information centre on the machine. Linking in the cloud is effected via a gateway. Both the Profibus in the PLC for time-critical and process-relevant data and the OPC UA protocol to the Human-Machine-Interface (HMI) 26
for other information are used to ensure the data exchange to the machine controller with CELOS®. Knowledge-based added value A total of more than 60 additional sensors continuously measure vibrations, forces, temperatures and pressures on the sensor-intelligent DMC 80 FD duoBLOCK® and report the results to the evaluation unit via which the information is both sent to CELOS® and made available to the cloud. Whereby the results of both pilot machines are analytically evaluated in the cloud thus increasing the quality of the forecast even further. Maximum availability “Every day and every detected deviation from the preset standard parameters will enhance the informative value of the data analysis”, promises Alfred Geißler. After all the algorithms were permanently updated on the basis of the continuous data evaluation, so that ever more targeted status information with ever more qualified predictions of occurrence could be derived. And Martin Schreiber stresses: “This should enable us to come ever closer to maximum possible availability via the intelligence of the machine, sensors and evaluation.” Whereby, according to Martin Schreiber, the higher availability is the result of better machine utilization and more efficient planning of maintenance measures. ”In addition“, maintains Alfred Geissler, “the overall machining value added is higher due to the numerous possibilities arising from process and production optimization. And what is more thanks to the knowledge base described above, it is possible to make reliable forecasts concerning the quality of the workpiece during or rather immediately after production.” Cooperative partnership It will be interesting to see how the customers react to the innovation project “Machine Tool 4.0”. The EMO presentation was already a milestone for DMG MORI and Schaeffler Technologies – especially in view of the close cooperative partnership between the companies that took place within the framework of the project. “It would never have been possible to realise such a complex task in such a short time and with such high (practicable) quality had we worked alone”, sums up Alfred Geißler. Finally, Martin Schreiber brings the customers on board as well: “The close interconnection between manufacturers and suppliers is only the beginning. More than anything Industry 4.0 needs open interaction between all the parties involved in the value-added chain.” Data protection and data security Whereby DMG MORI and Schaeffler Technologies are fully aware that the issues of data protection and data security will be the next great challenges that need to be addressed if the elementary confidence so vital for Industry 4.0 solutions is to be achieved. “We are all well-acquainted with the problem of handling sensitive data“, they all claim in unison. “That is why we will do everything in our power to work together with users and other potential partners to find a secure communication environment,” both Alfred Geißler and Martin Schreiber agree.
Japan humanoid robot sells out in 1 minute Softbank said that 1,000 units of “Pepper” were sold out in just one minute on Saturday. Softbank began accepting orders at 10am (8am Thailand time) on Saturday. Delivery will start in July. By the end of July the company will announce when it will sell the next batch of the robot, the firm added. Priced at 213,840 yen (58,600 baht), the robot is claimed to be the world’s first personal robot capable of reading emotions via its camera, touch sensors and microphone. Softbank plans to begin selling “Pepper” for corporate use, such as to use as a receptionist or to provide other customer services. Softbank also aims to begin selling it overseas possibly later this year.
Source: Bangkok Post
Masayoshi Son, chief executive officer and founder of Softbank Corp, stands by a humanoid robot, named “Pepper,” during a press conference in Urayasu, Chiba prefecture, on Thursday. (Kyodo photo)
How a grocery delivery service became a red hot robotics company
“Ocado, a UK-based grocery delivery service, has spent more than a decade investing in warehouse technology. Now an ambitious new robotics project has hardware-hawks scratching their heads”
Forget Amazon’s delivery drones. Robots are primed to change the way home shopping services operate, but the most substantive shift will happen in the warehouse, not at your front door. Ocado, a UK-based online grocer that logged $1.5 billion USD in revenue in 2014 and turned its first profit after 15 years this February, recently announced that it’s developing autonomous humanoid robots to augment and assist its human workforce. “The ultimate aim is for humans to end up relying on collaborative robots because they have become an active participant in their daily tasks,” says Dr Graham Deacon, Robotics Research Team Leader at Ocado Technology. “In essence, the SecondHands robot will know what to do, when to do it and how to do it in a manner that a human can depend on.” To get a sense of what these collaborative robot helpers will be doing, imagine an Ocado warehouse. Conveyor belts zip colorful baskets to and fro along diverging paths, placing them in front of an army of human workers who pack them full of groceries. The warehouse is full of machinery, and all of it requires careful and constant maintenance. To perform 28
that maintenance, a second brigade of human mechanics fans out to tinker, optimize, and fix the precise mechanisms that keep modern packing and shipping warehouses buzzing. It’s these workers, the maintenance men and women, that SecondHands is initially being designed to assist. If the image of a humanoid robot handing someone a wrench is quaint, the project’s aims are actually something of a moon shot. According to Deacon, the robots will “progressively acquire skills and knowledge needed to provide assistance. In fact, it will even anticipate the needs of the maintenance technician and execute the appropriate tasks without prompting.” In part it will do this by evaluating the pose of the human, a difficult thing for a robot because it requires deft navigation of a 3D environment, and intuitively offer help when it senses the worker is struggling. Collaborative robots have come a long way, but that kind of intelligence would make Ocado’s industrial robots the first of their kind to be deployed on a warehouse floor. This is actually the second time in as many months that Ocado has made news for its robotics ambitions. In May,
the company filed a patent application for a machine that can automatically pick and pack groceries, which would drastically reduce the need for that first army of human workers. Much of Ocado’s warehouse systems are already automated, the result of a concerted effort since its founding in 2000 to increase warehouse efficiency through technology. “Ocado is always looking for ways to enhance its customer proposition through the development of industryleading and proprietary technology,” read a company statement released in May.
“The robots will progressively acquire skills and knowledge needed to provide assistance. In fact, it will even anticipate the needs of the maintenance technician and execute the appropriate tasks without prompting according to Deacon”
That “proprietary” signifier is important. Amazon is also investing heavily in efficient pick-and-pack processes at its warehouses, but it is doing so in partnership with industrial robotics companies like Kiva. Ocado has taken a different tack, and as it refines its robotics systems for semi-structured warehouse environments and begins dabbling in concepts that are further afield, like artificial intelligence, the result may soon be an unlikely hybrid: a grocery delivery company that makes a good chunk of its revenue licensing the robots it develops.
RFID AND WIRELESS TECHNOLOGY
RFID technology will have a big role to play in the smart factory of the future, enabling ‘things’ to communicate in real-time with manufacturing systems.
“In Europe we call it Industry 4.0, cyber-physical systems and the ‘internet of things’ (IoT). In America it comes under the umbrella of the Smart Manufacturing Leadership Coalition or the Industrial Internet. However, we are all alluding to the same thing – the fourth industrial revolution and the vision of tomorrow’s manufacturing – the ‘smart factory “ The ‘smart factory’, which industry experts say will be upon us within the next two decades, will see machines, raw materials, and products communicating within an IoT to cooperatively drive production. In other words products will find their way independently through the production process. The goal is highly flexible, individualised mass production that is costeffective. Commenting on this, Mark Lynch, managing director of the Fairfield Group said: “We worked with Siemens on a project for BMW recently who are using RFID to enable mass manufacturing capabilities to encompass the bespoke requests of their customers. At the point of order the customer selects certain aspects of their vehicle from its sunroof to the latest in in-car entertainment functionality. An RFID tag is mounted in the engine of each BMW at the UK plant. The tag communicates with the production line system to drive its processes to add customer specifics as the car is built. This ensures the mass production line runs without extensive interruption whilst meeting the bespoke needs of BMW’s end customers. This is a clear example of where we can see Industry 4.0 principles in practice today.” 30
Smart Factories of the future will rely on both internet technologies and technologies such as RFID that enable ‘things’ i.e. components, parts, products to communicate in real-time via radio waves with manufacturing systems hosted on the cloud. Each item or ‘thing’ is expected to have its own IP address. RFID technologies have been advancing alongside web technologies independently for the past 70 years. The introduction of ‘packet networking’ saw very early signs of the Internet emerging in the 1950s and the earliest use of RFID technology can be traced back to World War II when a secret British project developed a system that would identify whether approaching aircraft were friend or foe using RF technologies. The fourth industrial revolution will see the two technologies come together as the web and the physical world meet. We have all experienced the revolutionary impact the Internet has had on culture and commerce since the early 1990s but not many of us are aware of how RFID has developed and why it will play a major part in the fourth industrial revolution and the emergence of smart factories in the next
RFID AND WIRELESS TECHNOLOGY RFID explained RFID (Radio Frequency Identification) is grouped under the broad category of ‘automatic identification’ technology. It is a technology that transmits the identity of an item wirelessly using radio waves. Like bar codes and optical character recognition, RFID has been developed to reduce the amount of time and manual labour required to capture data about specific items. An RFID solution generally involves a tag and a reader. An RFID tag is a microchip attached to a radio antenna mounted onto a substrate of some kind which can store anywhere from 1 bit up to 64 kilobytes of data (this is advancing as we publish). In terms of manufacturing this could be product or shipment information, manufacture date, sell-by date etc. To retrieve the data on the tag an RFID reader is required. This is a device that has one or more antennas that emit radio waves and receive signals back from tags. The reader then passes the data in a digital format to a computer system.
bar code standards, has gone on to develop an EPC (Electronic Product Code) for RF Tags as well as EPCIS that enables trading partners to share information about the physical movement and status of products as they travel throughout the supply chain. As for RFID tag pricing – it is all relative. There are many tags to choose from and different tags at different prices are required for different reasons for applications. The simple fact remains that if an RFID solution delivers great return on investment organisations will invest. As demonstrated by the BMW example, today’s manufacturers need to have the capabilities to launch new products incorporating innovative technologies without a lengthy or costly modification of their production lines. On the other hand they must be able to produce even the smallest of quantities (lot size of one) without increased costs in order to satisfy the varied needs of their customers. Mass customisation is the key
RFID tags can either be passive or active. An active tag has an on-board battery that regularly transmits its ID signal. A passive tag is activated when in the presence of an RFID reader. The earliest use of RFID technology can be traced back to World War II when a secret British project came up with a system that would identify whether approaching aircraft were friend or foe. They put a transmitter on each British plane. When it received signals from radar stations on the ground, it began broadcasting a signal back that identified the aircraft as friendly. RFID works on this same basic concept. The reader sends a signal to a tag which wakes up and either reflects back a signal (passive RFID) or broadcasts a signal (active RFID). Advances in RF technologies continued through the 50s and 60s and companies began marketing anti-theft solutions using radio waves. EAS (Electronic Article Surveillance) tags were attached to packaging and turned off at the check-out when paid for. The readers positioned at retail doorways would detect a tag that had not been switched off at the check-out triggering an alarm. The first RFID patents in American were recorded in the 70s and the US Government used RFID to track nuclear materials in the 1970s and to management toll payment systems in the 1980s. RFID technology began with low frequencies and developed to higher frequencies throughout the 80s into the 90s and then came UHF (ultra high frequencies) which led to far longer read ranges (up to 6m in good conditions) and faster data transfer. Despite all the hype of the 1990s the cost of tags and lack of international RFID standards are cited as the two main reasons why RFID technology has not been embraced as quickly and as widely as anticipated, despite its success in many applications, such as anti-theft systems for cars and payment solutions such as contactless smart cards. GS1, the organisation that manages
to delivering an extensive product portfolio without dramatically increasing warehousing and logistics costs. This is what the smart factories of the future promise to deliver and in some cases utilising RFID they already are beginning to. Mark Higham, general manager, Process Automation at Siemens said: “Siemens is fully committed to transforming Industry 4.0 from vision to reality for its customers. RFID is a key enabling technology within this concept and will support the drive towards the intelligent factories of the future. Fairfield are at the forefront of this revolution and, as a key partner to Siemens, and are helping companies transform their production processes with RFID technologies.” The Fairfield Group have been delivering auto ID solutions since 1982 and are often described by their customers as the glue bringing all of the relevant parties together. A typical RFID project could include consultancy, software, systems integration, RFID tags and readers and other hardware. The Fairfield Group have expereince across the range of technologies available in this field in addition to RFID – including bar coding, 2D codes, UDI, laser marking and coding, key dots, OCR, verification, vision and code checking solutions. Sources: Controlengeurope 31
ELECTRIC AND POWER
Singapore Power And EDB To Establish Centre Of Excellence SP is currently calling for industry companies to participate in SPEAR. Projects will be selected via a competitive and merit-based process, with awards expected from the fourth quarter of 2015 onwards. Source: iiasia online
Bukit Asam Looks to Juice Up Malaysia, Southeast Asia by 2020 With Riau Power Plant
Singapore Power (SP) has launched the Singapore Power Centre of Excellence (CoE) for Energy Development and Piloting at an initial investment of S$30 million (US$22.72 million). The CoE will drive the innovation and commercialisation of next-generation energy network technologies, for greater reliability and efficiency of Singapore’s infrastructure. The CoE, supported by the Singapore Economic Development Board (EDB), will develop, pilot, and integrate cutting-edge technologies in Singapore’s infrastructure networks. For example, remote sensors and intelligent drones could be deployed to perform monitoring tasks, freeing up skilled staff for higher order work. SP will form a dedicated 20-man team to spearhead the CoE. This core group will develop expertise in the development, testing and integration of new technologies in Singapore. The CoE will test-bed these technologies to validate technical viability, integrate them with SP’s networks, and eventually commercialise them. This will also support SP’s objective to build future-ready networks and capabilities, to deal with the global trends such as the drive for smarter and greener performance, as well as the adoption of renewable sources. In conjunction with the launch of the CoE, SP also announced the Singapore Power Energy Advanced Research and Development (SPEAR) programme as the CoE’s first initiative. Examples of technologies to be explored under SPEAR are in the areas of instrumentation and control, grid communications and smart energy management. 32
Jakarta. Indonesian state-owned coal miner Bukit Asam plans to start supplying electricity to Malaysia by 2020 following the completion of a coal-fired mine mouth plant in Riau – its first step to joining a region-wide power grid. “We’re currently waiting for a feasibility study on the power plant in Riau,” Milawarman, the Bukit Asam president director, said at a conference in Jakarta on Monday. “If the feasibility study is approved and we receive approval from both the Indonesian and Malaysian governments, the assumption is that we can start building in 2017. “This way, we will not only export just coal, but we can also export electricity, which is much greater in value,” he added. The company expects to spend $1.8 billion to $2.4 billion on the new plant, but has not yet decided where it will get the funding from. Once built, the plant in Riau’s Peranap district will be able to generate 800 megawatts to 1,200 megawatts of power, Bukit Asam says, possibly consuming up to six million tons of coal annually from the company’s mine nearby. The plan is to transmit that electricity to Malaysia through an undersea cable in cooperation with Indonesian state-owned power monopoly PLN and Malaysia’s Tenaga Nasional, according to a joint development agreement signed in 2012. Once it is transmitting to Malaysia, the company can swiftly tap into the planned Asean Power Grid, Milawarman said. The grid is an initiative dating from 1998 by the 10 member states of the Association of Southeast Asian Nations for an integrated regional power grid. Total investment for the grid is estimated at $5.9 billion. Milawarman said Bukit Asam hoped to secure regulatory approval for the power plant by the end of the year, citing possible competition from China, which is also looking to supply the region through the regional grid. Source: Jakarta Globe
ELECTRIC AND POWER
Record year for Renewable Energy Power; Heat, Transport Stay Fossil
The growth of renewable energy outpaced that of fossil fuels in the electricity sector last year, with a record 135 gigawatts of capacity added from wind, solar, hydropower and other natural sources, a new study shows.
That’s more than the generating capacity of all nuclear reactors in the United States and slightly less than Germany’s installed capacity from all power sources. The annual report released early Thursday in Europe by Paris-based REN21, a nonprofit group that promotes renewable energy, underscored how China, the world’s top consumer of coal, has become a global leader in clean energy, too. It also highlighted that while renewables now account for 28 percent of the world’s electricity-generating capacity, they still account for only a tiny share of how we heat and cool buildings and fuel our means of transportation. “The share of renewables in the power sector will continue to grow. We see that already, especially in emerging economies,” said Christine Lins, executive secretary of REN21. “But we need attention to the heating-cooling sector and transport.” Renewable energy’s share in all forms of energy consumption — currently about 10 percent — will have to increase 34
dramatically to fulfill the vision that President Barack Obama and other leaders of the Group of Seven wealthy economies endorsed last week. To fight climate change, they called for deep cuts in heat-trapping carbon emissions and all but eliminating them by the end of the century. Meanwhile, global energy production must surge to meet the demands of developing economies and a growing world population. The fossil fuel industry and many energy experts say that can’t happen without fossil fuels, even in the electricity sector, where coal remains the top fuel. “Renewables will grow but that doesn’t mean coal is going away,” said Benjamin Sporton, head of the World Coal Association. Sporton said India is commissioning 20GW of coal-fired power generation every year. “And they have a further 118GW under construction or approved,” he added. Supporters of renewable energy say the world is already “decoupling” carbon emissions from economic growth, pointing to preliminary data from the International Energy Agency
ELECTRIC AND POWER
showing that carbon emissions from the energy sector didn’t rise last year even though the global economy grew by 3 percent. However, earlier this week the IEA said that, among other measures, investments in renewables need to increase from $270 billion last year to $400 billion in 2030 to support a transition to a low-carbon economy. Paolo Frankl, the head of IEA’s Renewable Energy Division, said REN21’s figures matched research by his own agency, confirming a clear upward trend in renewables. The REN21 report said renewables accounted for almost 60 percent of the global power capacity added in 2014. Wind power made the biggest jump among the renewables in 2014, with 51GW of new capacity, almost half of it in China. “This shows that countries are turning towards clean energy to meet their energy needs, rather than fossil fuels that are driving climate change,” said Jake Schmidt of the Natural Resource Defense Council, a U.S. environmental advocacy group.
Solar power also expanded, but from a low level; it accounts for only 1 percent of global electricity production. Geothermal power added just 700MW of capacity, half of it in Kenya. Other renewable sources, such as ocean energy from tidal forces, are not yet having any significant impact. In heating and cooling of buildings and industry, which accounts for about half of global energy consumption, there was little change from the year before, with renewables representing about 8 percent, mostly biomass. In the transport sector, dominated by oil-based fuels, the impact of renewables remained small despite growth in biofuels. In road transport their share was only 3.5 percent in 2014, up from 2 percent in 2007, Lins said. As fuel for jets, renewables are still in the experimental stage. The report said at least 164 countries have set targets for renewable energy and about 145 had policies in place to support it. The authors called for governments to increase support for renewable energy, particularly in the heating and cooling sector.
DID YOU KNOW?
What Was The World’s First Robot?
“When we think of robots, we normally think of electronic machines in the shape of humans – like cyborgs or androids – or other computerized autonomous devices like the Roomba. But the definition of the word ‘Robot’ covers much more than that”. The definition of Robot is any machine or mechanical device that operates automatically or semi-automatically. This means that what is considered “a robot” need not be limited to being powered by electricity. Though, over the last century, we’ve seen an explosion in devices that are powered by some form of electricity. By far, the most prevalent usage of modern robots is in the workplace on production lines. They are used specifically to make production more efficient for the company, cheaper for the consumer and safer for the employees. But where did the word come from?
DID YOU KNOW?
Origin Of The Word “Robot” The word “Robot” was coined in 1920 by Karel Capek and his brother, Josef Capek. Karel was a Czech writer looking for a word to call the artificial creatures in his play. Unhappy with the word laboři (or ‘workers’ in Latin), his brother suggested roboti from the Latin word robota (meaning ‘serf labor’). In 1944, science fiction writer Isaac Asimov decided to expand on that and coined the word “Robotics” for use in his short story ‘Runaround‘. It later became a recurring theme in many of his books which helped to spur popularity and increase usage of the word.
What Was The World’s First Robot? Aside from mythological tales which include mechanical servants built by the Greek gods, the clay golems of Jewish legend and clay giants of Norse legend, the first real documented instance of a robot was in the 4th century BC by the Greek mathematician Archytas. He created a wooden, mechanical steam-operated bird that he called “The Pigeon”. The bird is believed to have been suspended from the end of a pivoted bar, while the apparatus revolved by puffs of compressed air and steam. Documentation of “The Pigeon” was found in the writings of Heron of Alexandria, who described it as “operated by water, falling weights, and steam”. Not only does it lay claim to the first known robot, but it is also the first documented record of a scientist attempting to figure out how birds fly.
What About Modern Robots? Robots and robotic technology is evolving at an ever increasing pace. We’ve sent robots into space to explore planets for us, into nuclear reactors, and even into hostile situations in place of soldiers in the war on terror. The industry itself is branching out in unpredictable, yet exciting ways. For instance, this strangely life-like (yet unsettling) robot shown in the video below is a robotic “pop star” which sings and dances for an audience (be warned, it is a tad creepy):
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Published on Jan 18, 2016
Published on Jan 18, 2016
AUTOMATE is an Automation, Electrical and Manufacturing industry magazine specially tailored to the Indonesian market and also to educate th...