PACE AUG 2019

AUGUST/SEPTEMBER 2019 | VOL.72 NO.4 | Est. 1953

SINGLE SOURCE TOTAL

AUTOMATION

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AUGUST/SEPTEMBER 2019 | VOL.72 NO.4 | Est. 1953

INSIDE PACE

Gas Engines

The Industry 4.0 Facility

Cloud Computing

Highlights from Engineers Australia event

Total Construction talks about building the factories of the future

Myths and facts about cloud systems in industrial settings

Post Print Approved PP100008186

GETTING INVOLVED IN RESEARCH COLLABORATION

EXCLUSIVE:

How a confectionary machine employs motion control for optimum results

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CONTENTS

Managing Director: John Murphy Publisher: Christine Clancy Group Managing Editor (Northern): Syed Shah Editor: Mike Wheeler Ph:(02) 9439 7227 mike.wheeler@primecreative.com.au

IN THIS ISSUE 26

Assistant Editor: David Loneragan Ph: (02) 9439 7227 david.loneragan@primecreative.com.au Sales/Advertising: Zelda Tupicoff zelda.tupicoff@primecreative.com.au Production Coordinator: Janine Clements Ph: (02) 9439 janine.clements@primecreative.com.au Design Production Manager: Michelle Weston

31

Art Director: Blake Storey Designers: Madeline McCarty, Kerry Pert SUBSCRIPTIONS: $99 p/a incl GST NZ: $A109 p/a & OS: $A119 p/a

16

Editor’s Comment 6

Subscriptions: Bobby Fung Ph: (03) 9690 8766

News 8

The IICA NSW Chairman Peter Veron on the association’s latest events.

Research & Development 16

Digital Connectivity 31

Industrial Gas Engines 21

Cloud Computing 32

Industry 4.0 24

Women in Industry 34

Process Automation 26

New Products 37

How can companies collaborate with research institutions to push innovation forward?

Copyright PACE is owned by Prime Creative Media and published by John Murphy. All material in PACE is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on information published.

The opinions expressed in PACE are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated.

Engineering experts speak about the efficiencies of of gas engines Total Construction talks about building solutions for industrial automation

© Copyright Prime Creative Media, 2019

How a machine built for a candy manufacturer employed the latest in motion control technology

Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format.

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ON THE COVER

Sydney Office Suite 303, 1-9 Chandos Street, Saint Leonards, NSW 2065, Australia

Gas Engines

The Industry 4.0 Facility

Cloud Computing

Highlights from Engineers Australia event

Total Construction talks about building the factories of the future

Myths and facts about cloud systems in industrial settings

GETTING INVOLVED IN RESEARCH COLLABORATION

MOVI-C®

Premium efficiency Higher operational safety Robust performance Extended service life and longer maintenance intervals Adaptable to specific applications

Choose success - start a conversation for your future, today:

MELBOURNE | SYDNEY | BRISBANE | MACKAY | TOWNSVILLE | PERTH | ADELAIDE

Post Print Approved PP100008186

is the complete solution for your automation tasks. With its four fundamental modules – engineering software, control technology, inverter technology and drive technology – SEW–EURODRIVE offers a complete modular automation system from a single source.

1300 SEW AUS (1300 739 287)

www.sew-eurodrive.com.au

EXCLUSIVE:

Treotham presents the latest igus solutions for data and energy supply An outline of what is important – and what is not – in the industrial cloud space Rockwell Automation’s Jasmin Perry on her journey in the process control sector

Getting on board with Industry 4.0

AUGUST/SEPTEMBER 2019 | VOL.72 NO.4 | Est. 1953

INSIDE PACE

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Comment 29

How a confectionary machine employs motion control for optium results

Increasingly, manufacturers and others in the industrial space are looking towards implementing Industry 4.0 solutions. With the federal and state governments providing grants for SMEs and entrepreneurs looking to develop innovative and highly productive solutions, companies are trying to figure out how to get on board.

In this issue of PACE, we look at how Industry collaboration with research institutions is one of the fruitful paths

forward for those looking to get on board with smart technologies and methods. The NSW Smart Sensor Network (NSSN) event in early July, provided some insights on how manufacturers can link with researchers, In this issue, we also talk to Total Construction about the launch of its Engineering Construction Group, and its ambition to build the Industry 4.0 facilities of the future.

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 5

COMMENT

EDITOR’S MESSAGE

Mike Wheeler Editor

Universities offer a helping hand

Industry 4.0 and the Industrial Internet of Things (IIoT) are the watchwords of the manufacturing world today: make your way to any industry exhibition or conference event and you will be certain to hear them intoned with – perhaps excessive – regularity. But there is a reason why these concepts have come to dominate discussion across the industry: the technologies, methods, techniques and business models to which they refer offer to enhance productivity and growth while reducing costs and waste.

But while small- and mediumsized enterprises (SMEs) looking to make the move into advanced manufacturing might find these prospects alluring, many have little idea where to start. While there is

news about various government grant programs with open applications and various research institutions offering a leg-up, these smaller players – who would benefit tremendously from taking up innovative techniques, technologies and processes – can sometimes wonder what the best way forward actually is.

In our cover story, we explore how SMEs can benefit through collaboration with research institutions – and how it doesn’t have to be that hard. The federal and state governments have established several bodies that can function as intermediaries between industry and universities. The Advanced Manufacturing Growth Centre (AMGC) and the Innovative

6 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

Manufacturing Collaborative Research Centre (IMCRC) have become familiar to many. A less well-known organisation, focussing on linking up industry with smart sensor research, is the NSW Smart Sensor Network (NSSN). This article also details of some of the discussions that occurred at NSSN’s first “Successfully Adopting Smart Sensing Technologies” event, which took place in July at Western Sydney University’s Launch Pad in Werrington.

Total Construction is a highly experienced construction company, well-known for its work in the food and beverage and energy sectors. It is now launching an Engineering Construction Group (ECG) that will

focus its efforts on offering the skills and experience it has developed to the wider industrial sector. In this issue, PACE talks to Total Construction’s James Bolton and Rob Blythman about how the company is striving to build the Industry 4.0 facilities of the future.

Lastly, following on from this year’s Women in Industry Awards, we have featured an interview with one of the finalists of that event.

Jasmin Perry is a young key account manager at Rockwell Automation.

Over her career she has continued to push forward her interest in the process control sector and expand her knowledge of the field. Her passion and her success were recognised with a nomination for the Rising Star Award. PACE

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NEWS

Kogan Creek Power Station to receive $90 million overhaul

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$90 million overhaul is to be carried out at the largest generating unit in Australia at CS Energy’s Kogan Creek Power Station.

Queensland Energy Minister, Dr Anthony Lynham, said approximately 400 contractors would be on site for the 77-day program of works, which run until 27 September.

“Overhauls provide short-term employment opportunities for people with the skills and expertise required to undertake maintenance and upgrades to the power station,” Lynham said.

“The Palaszczuk Government is focussed on regional jobs and building infrastructure and this includes ensuring the current infrastructure is in tip-top running condition and in the process generating employments opportunities.”

Lynham said principal overhaul contractors Downer Group, Siemens and Intertek were providing the majority of the workforce including electricians, boiler makers, riggers, fitters, welders, scaffolders and

The overhaul would bring a real economic boost to Chinchilla.

crane drivers.

“Locally-based contractors also have been engaged to undertake parts of the project works including RiE Group, Healy Contracting and Day Break-Milne.

“Local arms of other national and international businesses are also involved, such as Veolia, Amalgamated, Enzed and Rexroth.

“These contractors will work

alongside Kogan Creek’s permanent workforce of 111 people.”

Lynham said the overhaul would bring a real economic boost to Chinchilla and surrounding communities, both from the extra workers onsite and the flow on-benefits to local service industries such as accommodation providers, caterers and transport companies.

Kogan Creek’s last major overhaul

was carried out in 2016. This overhaul will include a range of inspections, maintenance and upgrades of the power station equipment to ensure it continues to operate reliably, particularly over the summer peak demand period.

Lynham said Queensland had ample power generation to meet electricity demand while Kogan Creek Power Station is offline for the overhaul.

“This is essential work, being taken to ensure continuity and reliability of supply for Queensland and creating employment and added prosperity to our regions,” he said.

Kogan Creek Power Station commenced operations in 2007 and is one of the most efficient coalfired power stations in the National Electricity Market. The power station features the largest single generating unit in Australia and water efficient dry cooling technology.

CS Energy also owns the neighbouring Kogan Creek Mine, which supplies black coal to the power station. PACE

RecordPoint to set up AI, engineering hub in Melbourne

W

ith support from the Victorian government, a global cloud-based records management company will base its Asia-Pacific headquarters in the state, providing more jobs within artificial intelligence (AI) technology sector.

RecordPoint – which partners with Microsoft – will establish the facility in Melbourne, which is also to serve as the company’s AI and Engineering Hub. This will lead to 100 new jobs in data science, software engineering, data

analytics and machine learning.

“RecordPoint’s investment in Victoria is testament to our position as Australia’s top tech city, with leading capabilities in advanced technologies such as artificial intelligence,” said state economic development minister Tim Pallas.

The investment will reportedly enable RecordPoint to improve its product offering in records management, boost its export reach to the Asia-Pacific region and build on Victoria’s capabilities in fast evolving

8 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

transformative technologies.

“As an Australian-founded company, being able to invest in Australia and tap into the diverse talent of Victoria’s growing tech sector will provide the resources needed to fuel our next wave of growth,” RecordPoint CEO Elon Aizenstros said.

RecordPoint enables organisations to manage records from multiple services and platforms, ensuring information is always safe and under control.

The company’s clients include public sector agencies, such as the Victorian

Department of Education and Training and the Australian Securities and Investments Commission, and regulated commercial industries including energy resources and financial services in the United States and the UK. The arrival of RecordPoint to Melbourne is one of the largest AI investments facilitated by the Labor Government and follows in the footsteps of other IT heavy-hitters, such as Square, Slack and Zendesk. Victoria’s tech sector generates approximately $35 billion annually. PACE

NEWS

Research project to explore potentials of IoT sensor technology in infrastructure construction

A

n Internet of Things (IoT) project bringing together key industry and research partners will research new satellite navigation monitoring sensors for infrastructure design and construction projects.

Monitum, a Brisbane company of professional surveyors and geologists, has teamed up with researchers at QUT and the Innovative Manufacturing Cooperative Research Centre (IMCRC), in the Mthing project that aims to lower construction costs, create safer building practices and boost jobs in Australian manufacturing and construction.

The 18-month project will use advanced Global Navigation Satellite Systems (GNSS) signal processing techniques to record near-real time measurements of infrastructure projects that will be both more accurate and faster than using traditional manual measuring techniques.

The project aims to develop GNSS IoT sensors that will provide costefficient constant and high-precision monitoring that will connect to cloud services and provide instant alerts.

Currently, the cost of purchasing and maintaining precise positioning sensors restricts their viability for mass monitoring applications. The Mthing project aims to produce sensors with a lower cost that will give them greater market potential for broader uses.

Monitum principle and director, Lee Hellen, said the research was a step in the right direction for jobs in a knowledge economy and advanced manufacturing in Australia.

Hellen said the research, by preventing unforeseen downtime, could save the construction industry millions of dollars in lost productivity.

“Australia is seen as a global leader in measurement, engineering and

The 18 month project will use GNSS signal processing techniques. construction knowledge,” Hellen said.

“However, Australian construction projects have become increasing more expensive to build and maintain and are growingly reliant on imported technology products and manufacturing to deliver agile and lean processes.

“Our research collaboration is invested in manufacturing a globally competitive monitoring IoT sensor system that will provide new opportunities for building and maintaining infrastructure in Australia.”

Hellen said the research could save the construction industry millions in lost productivity enabling, through time saved on more effective designs

and monitoring of construction and building maintenance.

QUT research leader, Professor Yanming Feng, said connected GNSS with embedded intelligence and data analytics offered effective solutions to many industry challenges.

“QUT is pioneering the research in this direction and we are pleased to explore research in this field with the Mthing collaboration project,” Feng said.

IMCRC CEO and managing director, David Chuter, said effective monitoring of civil structures required breaking new ground in technology, processes and services.

“The IoT has opened up new possibilities for Australia’s

manufacturing and construction industry – collecting, analysing and incorporating infrastructure information into practical applications and services that increase the efficiency, effectiveness and productivity of infrastructure design and construction projects”, Chuter said.

“The Mthing project explores these possibilities and creates, with its next generation of cost-effective GNSS IoT solution, new avenues for other Australian construction and manufacturing businesses to investigate and adopt IoT into their operations to future-proof and ensure sustained commercial outcomes for their business – both locally and through export.” PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 9

NEWS

Western Australian mines power forward with hybrid energy projects The project will be the first in Australia to use second-hand wind turbines which had been previously used in Germany.

T

wo Western Australian mines are switching to wind, solar and battery power as a way of improving reliability with lower emissions at a lower cost.

Gold Fields’ Agnew gold mine is already constructing a wind, solar, battery and gas hybrid facility at their site 1,000 kilometres north east of Perth, which has received $13.5 million in funding from ARENA. The hybrid microgrid will consist of an 18 MW wind farm with five wind turbines, a 4 MW solar farm with 10,000 panels and a 13 MW/4 MWh hour battery underpinned by a gas power station.

Meanwhile, Perth-based renewable energy developer Advanced Energy Resources are building a $11.2 million wind, solar and battery at picturesque Port Gregory, situated 100 kilometres north of Geraldton on the Indian Ocean.

This project, supported by $3

million from ARENA, will help to power the nearby GMA garnet mining and processing operation, providing up to 70 per cent of GMA’s electricity needs.

The project will be the first in Australia to use second-hand wind turbines which been previously have used in Germany. It is due to be commissioned in December.

The project also uses a novel approach to connecting wind and solar to the grid, overcoming the challenges of a weak, fringe of grid location through a design that decouples the wind, solar and battery from the grid via a DC link.

Both projects were announced at the Energy and Mines Conference in Perth, where ARENA CEO, Darren Miller, gave a keynote address that highlighted the long term opportunities for the mining sector to switch to renewable energy.

The mining sector produces 21 times more energy than Australia’s electricity sector, and consumes four

10 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

times more energy than the whole of the domestic economy.

Miller said that the projects will demonstrate how renewable energy can reliably provide the majority of the electricity required to power critical mining loads.

“Fringe-of-grid communities in mid-west Western Australia suffer from network outages, so this is a great step forward in creating a template for other electricity users in similar conditions, to replicate and reduce electricity costs and improve reliability and stability,” Miller said.

The Gold Fields microgrid is expected to provide 55 to 60 per cent of the mine’s total energy requirements, with the potential to meet almost all the requirements at certain times. To maximise the use of renewables, Gold Fields will adopt dynamic load shedding, forecasting of renewable generation and load management.

Distributed energy specialists EDL will design, construct, own and

operate the microgrid in two stages.

The first is due to be completed in mid 2019, installing solar panels to operate alongside the gas and diesel generators. Phase two will roll out the wind turbines, battery and microgrid and is expected to be completed in 2020.

EDL CEO, James Harman, said the company has seen momentum building for hybrid energy systems, particularly in remote off-grid locations.

“EDL is pleased to be an active contributor to Australia’s transition to sustainable energy,” Harman said.

“Our strong base of knowledge and experience from our successful hybrid renewable projects will enable us to provide Agnew gold mine with greater than 50 per cent renewable energy over the long term, without compromising power quality or reliability,” he said.

Once finished, it will be the first Australian large scale mine to be powered by wind generation. PACE

NEWS

RMIT recognised for leading blockchain research

R

Despite being in its early stages, blockchain is already proving to have a big impact.

MIT University has been ranked as among the world’s top universities for blockchain research by a leading provider of institutional grade cryptocurrency market data.

Kaiko, a digital assets provider, recently published its list of the top 10 universities, which shows RMIT coming in third position after the University of Cambridge and Massachusetts Institute of Technology (MIT).

In Kaiko’s outline of the contributions of the 10 research institutions, RMIT was praised for its “cutting-edge innovation” in combining

economic and technological research.

RMIT’s Blockchain Innovation Hub, led by Professor Jason Potts, has been engaging with government, policymakers and media to explore how blockchain could impact the regulatory and economic environment.

Publications from the multidisciplinary research team ranged from crypto-economic business strategy, to mapping the current and future layout of the blockchain economy.

Senior research fellow at the RMIT Blockchain Innovation Hub, Dr Chris Berg, said the announcement was a valuable recognition.

“RMIT is doing frontier research in

a frontier field,” Berg said.

“Even though blockchain is a very early stage technology, it’s already proving to have a big impact, with an enormous amount of interest from industry, government, academia, and the general public.

“I’m very proud of the research and engagement we’re doing at RMIT, it’s genuinely cutting-edge research with deep significance for the future of the global economy.”

In 2018, RMIT launched Australia’s first university short course on blockchain strategy in response to the growing importance of blockchain as an emerging industry. PACE

Australian Space Agency agreement

T

he Australian Space Agency has signed a Statement of Strategic Intent and Cooperation with Australian space start-up Myriota to enhance the capabilities of Australia’s space industry.

Anthony Murfett, deputy head of the Australian Space Agency, welcomed the statement and its contribution to the transformation of Australia’s space sector.

“This statement embodies the transformation we are witnessing in the space industry both here in Australia and around the world – it demonstrates that businesses of all sizes can make a significant contribution to Australia’s space industry,” Murfett said.

“The Australian Space Agency goal is to triple the size of the Australian space sector from $3.9 billion to $12 billion and create 20,000 new jobs by 2030. This statement highlights how

companies are contributing to the growth of the sector and how space technologies can help other areas of the economy.

“Myriota is a global leader in nanosatellite Internet of Things (IoT) connectivity, and their use of nanosatellite technology is used to solve issues affecting everyday Australians, including water and agricultural management in regional Australia.

“Combined with their commitment to education and diversity in Australia’s growing space sector, Myriota closely aligns with the vision outlined in Australia’s Civil Space Strategy.”

Myriota is an Australian company specialising in the provision of IoT data connectivity via low Earth orbit satellite that aims to enable Australian and global industries to obtain sensor and location data to digitally transform their businesses. PACE

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AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 11

NEWS

Industrial monitoring solution utilising AI and 5G implemented in Helsinki

A

joint pilot project by ABB, Atostek and Telia is exploring new industrial monitoring solutions based on 5G wireless technology and artificial intelligence (AI).

ABB is piloting the world’s first AI application using 5G wireless technology to support the assembly of drives at its plant in Pitäjänmäki, Helsinki. ABB is implementing the solution in partnership with mobile phone operator Telia and software engineering firm Atostek Oy, which specialises in industrial applications.

The AI application will support the plant’s workers by monitoring the assembly of the drives by camera and ensuring they are correctly assembled according to a customer’s order and applicable work instructions. The fast 5G connections will provide workers with real-time feedback and should make assembly significantly easier than following work instructions from a paper document, thereby helping to improve quality.

Atostek is responsible for the computer vision and the AI application.

Telia is providing the system’s highspeed 5G mobile connections and providing the computing capacity needed by the application in its data centre. The project is being implemented in stages and will be in full-scale production in June 2019.

The application is being applied to the power module assembly line, which is critical to production quality and demanding for employees as dozens of different versions of the same product are assembled on the same line.

“The potential of AI is strongest when combined with human expertise, and the goal of supporting employees in a new way is at the heart of this project,” said Chris Poynter, group vice president for ABB system drives.

ABB is piloting a world’s first in AI application using 5G wireless technology.

“At its best, this real-time quality assurance system not only improves production line quality and productivity, but also reduces the stress associated with human errors, which helps improve wellbeing at work.”

5G enables wireless technology to be applied much more widely than has so far been possible and this is

12 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

expected to significantly boost global production over the next few years.

By introducing the 5G AI solution, ABB and its partners are exploring how industrial applications that require high data capacity and high computing power can be implemented in scalable form in the future, regardless of location. For example,

the AI application could be integrated with ERP systems.

ABB’s drives plant in Helsinki is ABB’s leading unit in the development of low voltage drives. The plant has around 1300 employees. Globally, ABB’s drive business involves around 6,000 employees in a total of over 80 countries. PACE

NEWS

Two new automation courses to be offered in WA

T

wo new automation courses are to be offered by South Metropolitan TAFE in Perth from the second half of 2019, the first outcome of the Resource Industry Collaboration between the Western Australian government, South Metropolitan TAFE and Rio Tinto.

The Certificate II in Autonomous Workplace Operations will be delivered as a pilot VET for secondary students from Cecil Andrews College, Gilmore College, Baldivis Secondary College and Karratha Senior High School.

The micro-credential course, Working Effectively in an Automation Workplace, is a skill set that trade qualified workers and apprentices

can use to improve their skills in automation.

WA Premier, Mark McGowan, said that the courses were a great example of industry working in partnership with government to ensure our training sector creates a highly skilled workforce.

“These new courses will allow us to maintain our competitive advantage as a leader in automation technology in Australia and ensure local people have the skills for the new jobs that are being created through technological innovation,” McGowan said.

“They will also ensure the diversification of our economy and help Western Australians assist the mining

The courses will ensure the local state people will have skills for new jobs.

industry well into the future.”

The Collaboration includes Rio Tinto and other major employers, such as FMG, BHP and Komatsu, representatives from TAFE WA,

Scitech and The University of Western Australia, and was created by the McGowan government in 2018 to build the skills and capabilities of the Western Australian workforce. PACE

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NEWS

UNSW secures industry partnerships in China for robotics and water treatment research

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esearchers from the University of NSW (UNSW) that are working in the fields of robotics and environmental protection have secured two new industry partnerships during UNSW’s Torch research roadshow in China.

The delegation of 13 UNSW researchers from 8 schools met with more than 200 enterprises, technology transfer platforms and investment institutions during the roadshows held in Yixing, Shanghai and Guangzhou last month. The event, which aims to encourage global knowledge exchange and industry collaboration, involved companies from a wide range of research fields including health and biotechnology, environment, energy, materials and manufacturing, big data and analysis, imaging and AR/VR. Cooperation agreements were signed with two technology companies during the roadshow. The first, between the UNSW Centre for Transformational Environmental Technologies (CTET) and China Coal Technology and Engineering Group (CCTEG), will support collaborative research and talent exchange in the field of water treatment.

The project will be led by Scientia Professor David Waite from the School of Civil and Environmental Engineering, who is also executive director of CTET, UNSW’s first overseas research centre. The facility is dedicated to driving research and commercial opportunities in environmental protection, especially water treatment, resource recovery and environmental management and sustainability for coal mines.

Robotics engineering company Shanghai Acrobotics, founded by UNSW alumnus, Wayne Liu, signed

The partnerships will provide a further boost to driving innovation between UNSW and China. the second agreement to establish a joint R&D centre focussed on the development of robotic operating systems. Professor Claude Sammut from the School of Computer Science and Engineering will lead the project to create user-friendly interfaces and human-robot interactions.

Professor Ian Jacobs, president and vice-chancellor of UNSW Sydney, said the partnerships will provide a further boost to driving innovation between UNSW and Australia’s largest trading partner, China.

“Collaborating across sectors and across borders to expand our knowledge is increasingly important.

Our world so desperately needs answers to grand global challenges in such critical areas as climate change, artificial intelligence and health,” said Jacobs.

“The UNSW Torch Innovation

14 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

Precinct, the first of its kind endorsed outside of China, supports researchers and entrepreneurs to seek those answers. Torch is helping us better prepare for the future by advancing new research frontiers, and more effectively translating that research into real-world impact.”

The ongoing development of the Torch Innovation Precinct has provided opportunities for interdisciplinary cooperation, including a partnership between UNSW and Beijingbased manufacturer Goldwind Environmental Protection (Goldwind EP), announced during the 2nd Torch Innovation Week last November.

UNSW’s industry partner on photovoltaic energy, LONGi Solar, donated 15 high-efficiency single crystal components at the Roadshow to support the collaboration between

UNSW and Goldwind EP. The new project will conduct field trials in China using new desalination technology to provide high quality drinking water for remote villages in Xinjiang Province.

Warwick Dawson, director of Knowledge Exchange, said UNSW had achieved extraordinary success with its Torch Innovation Precinct over the last three years, establishing deep engagement with industry partners and building an increasing R&D investment pipeline.

“Delivering transforming and enduring global impact from UNSW knowledge, capability and new technologies can only be achieved through a generous spirit of partnership with end users in Australia and across borders,” Dawson said.

“UNSW places a high priority on strong and close relationships with industry partners. Social progress and economic prosperity are the desired outcomes from our bold and ambitious 2025 Strategy, and partnership with China through our Torch Innovation Precinct is one of the flagship initiatives under our strategy.”

The Torch Innovation Precinct at UNSW is an new partnership between UNSW-led research teams and Chinese businesses and industries with the capital and market access needed to translate Australian research into high-impact new products, processes and services.

UNSW has signed more than $75 million research contracts with 70 partners, with an additional $200 million worth of contracts under active discussion.

Flagship contracts include research and commercialisation in energy, environment, advanced materials, manufacturing and biotech. PACE

NEWS

Open Integration partners meet to discuss digitalisation

3

5 Open Integration partners gathered together at Endress+Hauser in Reinach, Switzerland, in late June to share their experiences and thoughts for the first time. A highlight of the event was a presentation from representatives of the chemical and pharmaceutical industries outlining how they benefit from the partner program during digitalisation of their processes – and what they would like to see in the future.

The goal of the Open Integration program initiated by Endress+Hauser can be summed up quickly: the simple, fast and manufacturerindependent integration of components and devices into various automation systems. And, almost more importantly, satisfied customers.

While it sounds simple in theory, when it comes to day-to-day system operation, it’s far from that. Even

the most experienced automation specialists have great respect for multi-vendor systems. That also applies to complete solutions from a single source. This is because digital communications – a precondition for the extensive use of existing intelligence in field devices and systems – places serious demands on integration.

With its Open Integration partner program, Endress+Hauser is inviting providers of control technology, fieldbus infrastructure, measurement technology and actuator systems to test and document the interaction of their products even more extensively in the interests of their customers. The cooperation partners include Auma Riester, Bürkert, Festo, Flowserve, Hima Paul Hildebrandt, Honeywell Process Solutions, Mitsubishi Electric, Pepperl + Fuchs, Phoenix Contact, Rockwell Automation,

Open Integration partners at the Endress+Hauser event in Reinach, Switzerland.

Schneider Electric and Turck.

The foundation of this effort is open communication standards (Hart, Profibus, Foundation Fieldbus, EtherNet/IP or Profinet), as well as open integration standards (FDT, EDD, FDI). With a nearly unlimited selection of options, the reference topologies represent practical combinations suitable for applications in the chemical, life sciences, food and beverage, oil and gas, power and energy, primaries and metal and water and wastewater industries.

The reference topologies take into account industry-typical requirements such as explosion protection, availability and redundancy. Each topology is thoroughly tested and documented in the lab in Reinach in conjunction with the partners, after which the recommendations are published.

And how do customers benefit

from the Open Integration partner program? Every problem that the integration experts discover prior to commissioning can be resolved at a much lower cost compared to fixing the issue in the field at some later point. Customers receive concrete, validated recommendations for automating their systems, which go well beyond established conformity and interoperability testing while ensuring seamless integration. In addition, they save time and money.

With developments such as IIoT and APL, users will face new challenges, plus integration testing will be given greater importance. This makes it even more important for the Open Integration partners to work together over the long term. The participating customer and provider representatives were in full agreement on this point.

Cyber security, in addition to the issue of connectivity, will play a key role in the future. The attendees agreed that effective strategies need to be developed to counter new entrants in the automation industry such as IBM or Amazon.

One thing was clear during the get-together in Reinach in early June: the process control industry wants open, interoperable systems instead of proprietary solutions. One of the users wants uniform, structured access to static information via QR- and RFIDsupported type plates in accordance with DIN 91406. Standardised diagnostics in line with NE 107 is also at the top of the wish list.

In the near term, Endress+Hauser wants to work with its partners to address these and other open issues with the aim of utilising Open Integration to offer customers even more value-add during digitalisation of their processes.

The common goal: satisfied customers who can extensively utilise the opportunities that digitalisation brings with little risk. PACE

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RESEARCH & DEVELOPMENT

Taking the leap: research collaboration as a path to industrial innovation The productivity-enhancing potentials of the technologies associated with Industry 4.0 are becoming increasingly attractive to manufacturers. But where can a small- or medium-sized company go to find out the right path forward? PACE takes a look at the benefits of industry collaboration with research institutions.

M

Mark Goodsell says that establishing collaboration between industry and universities would require a build-up of mutual trust.

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edia representations of Australia’s manufacturing sector today are often characterised by a curious blend of the old and the new, pessimism and optimism. On the one hand, manufacturing is often associated with country’s economic past, the post-war period, an era of mass production for domestic markets symbolised most of all by the automotive industry. This was a time in which the manufacturing sector achieved its highest contribution to Australia’s gross domestic product (GDP), hitting 25 per cent in the 1960s, according to statistics from the Productivity Commission. By 2006, this number had dropped to 10.5 per cent; in 2016, according to the World Bank, manufacturing accounted for approximately only 6.6 per cent of GDP. The closures of large automotive manufacturing plants in recent years have, according to a certain strain of media narrative, marked a kind of terminal point.

For some, indeed, it has become customary to preface any statement on Australian manufacturing with the qualifier “declining”.

On the other hand, recent trends such as the globalisation of supply chains, advances in digital and automation technologies, and a rising demand for customised, bespoke products, have opened up new opportunities for Australia’s manufacturing sector.

A widely-cited 2016 article co-written by then deputy director and science director at the CSIRO’s

Manufacturing Flagship Cathy Foley (now CSIRO’s chief scientist) and CSIRO director of manufacturing Keith McLean, titled “The Australian manufacturing industry is not dying, it’s evolving”, argued that despite the well-publicised decline of some manufacturing sectors in Australia optimism about the sector ought not be diminished.

“The innovation resulting from science and technology, such as automation, digitisation and new materials, has changed the equation of what it means to be a manufacturer.

Manufacturing is no longer a basic industry that employs low-skilled workers,” Foley and McLean wrote.

“Over the next 20 years, Australia’s manufacturing industry must transform into a highly-integrated, collaborative and export-focussed ‘ecosystem’ that provides high-value customised solutions contributing to global supply chains.”

And there is evidence that a shift is occurring. The same year in which Australia’s manufacturing sector dropped to 6.6 of GDP also marked the beginning of an almost 3-year growth trend across the sector.

From August 2016, the Australian Industry (Ai) Group’s Performance of Manufacturing Index (PMI) indicated expansionary tendencies across the industry. Despite recent difficult economic conditions, only in June this year has the measurement fell below the 50-point mark, indicating a mild contraction in manufacturing conditions and bringing to an end a 33-month consecutive run of growth.

Keeping the sector competitive,

RESEARCH & DEVELOPMENT

and thus enabling its further growth, is now seen as vital by both industry lobby groups and government departments. And it is the productivity-enhancing potential of new technologies and methods associated with name “Industry 4.0” that is most alluring.

These technologies and methods include robotics and automation, artificial intelligence and machine learning, additive manufacturing (otherwise known as 3D printing), nanotechnologies and advanced materials, along with internet of things (IoT) sensor technology and data analytics. According to Foley and McLean, these technologies unlock a greater capacity for more customised approaches to manufacturing, which suits the current Australian environment. “Small to medium enterprises (SMEs) make up 97 per cent of Australian businesses. So customisation is an ideal recipe for Australian SMEs to achieve global reach without the need for producing more goods than their competitors.”

Promising signs

In recent years, Australia’s federal and state governments have been encouraging the nation’s industrial sectors to transition to these more advanced methods, technologies and processes that, it is hoped, will improve their productivity and competitiveness in global markets.

In the weeks leading up to the federal election this year, the incumbent Coalition government announced that it would establish a $50 million Manufacturing Modernisation Fund, which aims to stimulate a further $110 million in business investment in new technologies and processes. The Fund, the government said, would provide grants to small- and mediumsized manufacturing companies to co-fund capital investments that enable them to scale-up, invest in new technology, and develop new highvalue products.

This announced investment builds on the government’s investment of $100 million in the Advanced Manufacturing Fund, its creation of the Advanced Manufacturing Growth Centre (AMGC), and its $40 million in funding for the Innovative Manufacturing

The NSSN’s “Successfully Adopting Smart Sensing Technologies” event was held at Western Sydney University’s Launch Pad. Cooperative Research Centre (IMCRC). These organisations, and others like CSIRO’s SME Connect, have been established to help link up manufacturers with Australia’s research sector, and with government grants, to facilitate the adoption of innovative technologies that enhance productivity.

At National Manufacturing Week this year, AMGC NSW and ACT state director Michael Sharpe said that it was vital that manufacturers utilised the pathways towards collaboration with research institutions.

“Collaboration is a key driver to become an advanced manufacturer.

We need more Australian companies working together, big and small,” Sharpe said. “And we also have to work with our world-leading researchers – we have some of the best researchers in this area and we have to tap into this resource. There is certainly a real growth opportunity for companies to collaborate and work stronger together.”

Sharpe was joined in his call for collaboration by Ai Group’s Mark Goodsell, who said that establishing these connections depends upon establishing trust – something that has, until recently, been difficult. “The starting point

of this collaboration story is that it is hard. It is hard because the Australian business culture in the past has not valued it,” said Goodsell. That is, collaboration with research institutions goes against the traditional business models that have been cultivated in Australia. “One of the things we have discovered about the Australian business psyche is that we have tended to value rugged individualism; our economic model was very inward-looking, without much focus on exports; the competition was down the road and you didn’t easily collaborate with them because they would rip you off. So, if you find that your early attempts to collaborate are difficult, there is a reason for that.”

And from the university side, they have not been encouraged to collaborate either, as institutions and as individual academics, as their status comes from publishing information, not giving it to someone else to monetise it. “We’re therefore coming to this collaboration from historically different viewpoints. The good thing is that it is changing, and we know it is changing because we are finding it hard; and we are only finding it hard because we are trying to do it,” said Goodsell.

This requires trust, something that Goodsell said is not easily purchased or gained. He said that Ai Group, AMGC, and other bodies have been trying to make collaboration easier by linking manufacturers to research institutions. “Trust usually comes from experience. But there is a lot of learning going on. Go visit your local university, find out what they are doing, find out what the funding models are, find out whom to talk to – and keep pounding away,” Goodsell said.

Supporting innovation in NSW

In NSW, which produces approximately one third of Australia’s total manufacturing output, generating around $33 billion, the state government is making moves to support the growth of advanced manufacturing in the state. In 2018, the NSW government released its NSW advanced manufacturing industry development strategy, which is targeting the development of highvalue, high-skills services in the state’s manufacturing sector, particularly in pre- and post-production processes such as R&D and design.

Alongside supporting access to NSW and Commonwealth funding

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RESEARCH & DEVELOPMENT

programs, one of the aims of the strategy is to “[S]trengthen the capacity for industry, government and research institutions to engage and collaborate”. Among the enabling bodies for this collaboration is the NSW Smart Sensing Network (NSSN). Established in 2016 with funding from the state government, the NSSN has particular focus on unlocking the potentials of smart sensor research in manufacturing and other industries, including the infrastructure and energy sectors.

In July, an event showcasing the possibilities of collaboration was held at Western Sydney University’s Launch Pad in Werrington.

Co-hosted by NSSN and the NSW Department of Industry, and attended by representatives from AMGC, the federal Department of Industry, CSIRO’s SME Connect team, along with several manufacturers, the event was the first in the latter’s “Successfully Adopting Smart Sensing Technologies” series, which will see similar events held at other partner universities.

Julie Lockyer, senior project officer at the NSW Department of Industry, said that the event was centred around encouraging partnerships between universities and industry by presenting successful examples of such collaboration. “One of the key areas of the state government’s development strategy is advanced knowledge, and what we’re doing is passing on that knowledge between universities and industry. More importantly, industry can see that return on investment through that partnership as well, from hearing what the benefits are of that advanced knowledge area,” Lockyer said.

“Another area that is of focus today is in advanced processes – we will look at the evolution of Industry 4.0 advanced technologies.

Manufacturing has to move, it has to move to that advanced level, and we need to support industry along the way.”

Anthony Morfa, NSSN’s business development manager, said the function of NSSN is to “build a bridge” between member universities in NSW with industry. “Our member universities are basically the strongest and most capable research universities

in NSW and the ACT and the research that is taking place at these universities is second to none,” Morfa said. “What our members are actually interested in doing is connecting with industry and understanding the challenges industry face and trying to participate and support industry as much as possible.”

Explaining “smart sensing”, Morfa said that it involves the use of advanced sensors in manufacturing to measure a range of variables, from machine temperature and vibrations all the way to data analytics, extracting the data and interpreting it in ways that add more value. “I think what makes a sensor actually ‘smart’ is the ability to take data, digest it, and then actually make smart decisions with it,” he said.

Across the NSSN there are approximately 550 experts working at over 110 different research institutes and centres in the smart sensor space. “They have specialised equipment, specialised knowledge and can immediately start working on problems with techniques that may not be available to every company,” said Morfa. “The take home message is that if you are producing any sort of data that can help you make a decision, there is going to be a way to collect that information, and there’s going to be a way to understand that with some sort of algorithm or software and to make that process that you’re working on a little bit easier.”

Morfa said that the relationship was a two-way one, with academics also being further propelled forward in their research and understanding.

“Researchers want to understand what’s going on in industry as it helps them have greater impact. A lot of researchers are doing research to improve society and improve the economy – it’s obviously very hard to do this if you’re not talking to industry itself,” he said.

Organisations like NSSN or AMGC, Morfa said, serve as a mediating point for companies looking to get involved with research institutions, reducing confusion and making communication between traditionally very different sectors much easier. “What you can start by doing is talking to someone like me

18 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

or Michael [Sharpe] and explain your problems. It might turn out that you would benefit from some R&D, and we can facilitate better connections with the universities. This process removes barriers because you don’t have to go speak to all the different universities and try and make an introduction yourself,” he said.

“What we do is we work with all of our member universities and try and help them understand what you are dealing with in your business, send out information to all the universities at once, and then

put together a list of all the top researchers that we can find that would be able to support something you’re interested in.”

From that point on, NSSN facilitates personal introductions help companies find the most suitable researchers. Morfa also said that it helps businesses understand how they might be best able to commercialise and upscale this research. “One of the wonderful things about being based in NSW is that there’s a huge number of companies that do prototyping, electrical engineering, do everything

RESEARCH & DEVELOPMENT

than just production. Manufacturing in today’s world means involvement in research and development and unlocking the value of world class researchers. We’ve got some of the best minds right here in Australia, and I’ve been able to take professors out of our great universities and onto the factory floor right across the state.

This is also a great opportunity for researchers – they learn something too because we’ve got some outstanding business people manufacturing right across the nation.”

Universities as a launch pad for industry

Getting involved in Industry 4.0 innovation can be made easier by collaborating with research institutions. you might need to take technologies that have been developed at the university and get them ready to be produced here in the state and eventually exported,” he said.

AMGC’s Michael Sharpe also shared the view that helping Australian manufacturers to effectively operate in a volatile economic environment involved enabling greater access to export opportunities.

And these, he said, are made more available by getting involved with cutting-edge research and providing innovative solutions. “Everyone said

you can’t bend corrugated iron, that it will break or crack or it will crease, yet there is a start-up company here that have done just that and they’re getting ready to export those machines globally,” Sharpe said.

He said that with manufacturing making up around 10 per cent of the Australian workforce, it is still an important sector of the economy.

But grasping the opportunities available via research collaboration would help unlock further potential.

“Manufacturing is much more than just making stuff – it’s much more

Western Sydney University’s Launch Pad, established in 2015 in partnership with the NSW government and corporate sponsors, provides facilities, assistance and resources for startup and high growth technology-based businesses in the Western Sydney region.

Dr Andre Urfer, business development team leader at Western Sydney University’s REDI Business team, said that around five years ago the university decided to make a change in direction towards branching out its research capabilities to industry. “The management at the time said to the researchers, ‘You are empowered and encouraged to go out there and start building research partnerships with industry – including not-for-profits, charities, small, medium, or large enterprises – and work on real life problems that you can provide the research solution to,’” Urfer said.

“The aim of REDI Business is to make it easier for people to engage with the university – it’s really about finding individuals that can work together fantastically on projects.

There are networks out there, and Launch Pad and any project you will have our university will eventually come through REDI business. And we’ll help you translate two different worlds, bring them on one page, make sure that budgeting is right, pricing is right and the contracts are right – and off you go.”

Asked how a company might get involved with the university, Urfer said that just beginning a conversation with the university was a good start. “Just get in touch, have

a chat together. We can figure out what exactly it is that you need, and I can look internally for the right researchers to come and have a chat with you about the problem and whether there is a solution that is on offer,” he said.

“Other options are at an event like today: if you start talking to a researcher in the audience and that leads to anything more, REDI business will be involved to facilitate that process.”

Among the examples of collaborations between SMEs and research institutions presented at the event was that of LA Services, a specialised welding and fabrication business based in western Sydney.

David Fox, LA Services’ general manager, said that the challenges for his company came from being shackled to old ways of doing things.

“This business had been going for 37 years and been doing the same thing for a very long time. The question was, ‘How do you shift that?’”

Fox said that the company had to go through a process of learning and understanding how Industry 4.0 technologies and processes could add value to a company working with very old industrial equipment and methods. “I didn’t see how it was going to relate to us. Initially, it was very hard to see that.” Fox said that talking with a variety of academics helped him to expand his understanding of the benefits of new approaches. “One of the ‘Aha!’ moments was when we were told to look upstream and downstream from our products, at areas where we could add further value to what we were already doing,” he said. “Today, three years later, we’re much clearer on how that might work in terms of shifting our business out to different areas that we never imagined and then we could tap into that with a different business model.”

Fox said clarity and concreteness around what Industry 4.0 could mean specifically for his company was important. “For us clarity across the landscape involved a definition of Industry 4.0 that suited us. The possibilities with big data, analytics and digital to physical transfer were the things that were put to us that we could actually hang on to.” PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 19

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INDUSTRIAL GAS ENGINES

Creating efficiencies in energy production Gas engines offer significant advantages over gas turbines in the efficient production of energy. A recent Engineers Australia event hosted three presentations covering the application and effective maintenance of these systems.

PACE reports.

O

n a cold early July evening, engineering professionals gathered at the sleek and stylish Brickworks design studio to hear presentations on the operation and maintenance of industrial gas engines.

The event, hosted by Engineers Australia, was attended by 100 industry professionals, with another estimated 300 joining via webcast.

The first speaker was Paul Gordon, Aurecon’s global service leader for power generation. Gordon has 17 years’ experience providing energy advisory services to clients for the development and implementation of projects including solar PV, solar thermal, battery energy storage systems, biomass hydrogen pumped hydro energy storage, LNG to power, gas turbines, reciprocating engines, and conventional thermal plant technology.

Gordon first spoke about developments in the energy market, how it is transforming, and what this might mean for Australia’s energy mix in the future. Among the changes he discussed were the move from centralised to distributed energy, and from thermal to renewable power generation. Gordon presented slides indicating forecast closures of coalfired power stations on Australia’s east coast. The retirement of these stations, he said, will mean it will have to be replaced moving forward. “This, coupled with the renewable energy target nationally, as well as state-based targets, means we’re going to see an increase in renewable energy installed in the network, and we see the bulk of that being installed as variable renewable energy (VRE), which will obviously increase that generation and have various flow-on effects to the

system, including recent trends in the National Electricity Market (NEM), such as reduced system strength, system security issues, lower inertial level,” said Gordon.

Further, as VRE generation on the network increases, there will be an increased suppression of the residual demand curve during daylight hours. The increased VRE, which is constituted of mostly solar PV, will potentially reduce the residual demand – demand that needs to be met by dispatchable generation sources such as traditional thermal

plants. “In the afternoon, as solar comes off, there’s a huge need for dispatchable generation to ramp up in the afternoon to meet that residual demand curve,” said Gordon. Another challenge, he said, is how existing thermal plant is managing this in terms of managing turndown and being available to ramp up. “So, there is going to be a need for more flexible generation as we move forward.”

Flexible generation is dispatchable generation that is flexible in terms of how quickly it can start up and be turned off, and in terms of its

Paul Gordon described how the use of gas engines fits into future of energy production.

Torrens Island Power Station. Barker Inlet Power Station will replace the aging facility, which has been in operation for 50 years.

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INDUSTRIAL GAS ENGINES

Kevin Anderson has been working on the Barker Inlet Power Station in Port Adelaide for AGL. efficiencies at part load. The demand for flexible generation is where gas engines enter the picture. There are already numerous gas engines installed around Australia, with significant numbers currently in operation in the Northern Territory and Western Australia. Historically, these have been smaller-scale installations. According to Gordon, moving forward, more and more large gas engine installations will take place.

AGL are in the midst of construction of Barker Inlet Stage One, which is a 210-megawatt gas reciprocating engine plant. The company is also looking installing plant in New South Wales, Newcastle, while APA has also announced plans for developing a project in Dandenong and has been shortlisted under the federal government’s underwriting New Generation Investment Scheme.

For peaking duties on the NEM, developers’ utilities have historically developers’ used gas turbines.

However, among the attributes of gas engines are greater efficiency in terms of fuel conversion than comparable aero or industrial gas turbines. Furthermore, another key beneficial attribute of gas engines compared to gas turbines is that they do not de-rate in output until the temperature hits around 40 °C, whereas gas turbines are highly sensitive to temperature. Gas engines also don’t de-rate as much at part load as gas turbines do, and by

aggregating a number of smaller units there is the flexibility to turn them off as there are lower dispatch requirements.

Gordon presented a case study detailing a project at a power station being developed at Owen Springs in the Northern Territory, where an existing aging thermal plant in the centre of town running on dual fuel, diesel and gas, was reaching the end of its life had various inefficiencies, high maintenance costs, environmental considerations and was due for retirement. The owner, Territory Generation, replaced the generation

Andrew Lo from ExxonMobil described the effectiveness of oil maintenance for gas engines.

22 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

capacity by expanding their Owen Springs power station. As part of the project there was a need that to make sure that the gas engines could operate efficiently in conjunction with the other energy sources on the network. Further, a battery energy storage system was put in to operate in harmony with the gas engines.

The plant has a highly variable low profile that ranges from 12 MW at minimum demand up to about 54-55 MW at peak demand and is highly seasonal in terms of variability. “It also has a huge amount of solar which can cause fluctuations in frequency on the grid and cause gas engines to ramp up and down, and as a result of this, the system operator there requires a large amount of spinning reserve to be operated which is inefficient, costly and not good for the environment in terms of burning gas. So, what was determined was to install a battery that could enable the gas engines to operate more efficiently,” Gordon explained.

“Overall the battery is undergoing final grid testing at the moment and is proving very successful in its ability to respond to frequency events and it also improves the overall efficiency of the gas engine, so one gas engine can be turned off and the other gas engines can operate at a higher load factor for improved efficiency, and, in the event one trips, the battery will hold up the network until one can fast start.”

The second presentation was from Kevin Anderson, who has over 34 of experience in the power industry.

He was an instrument fitter for six years and has since worked as a project engineer, a performance and efficiency engineer, an operations engineer and an operations manager.

He is currently assisting with project managing the build of the Barker Inlet Power Station in Port Adelaide for AGL. Anderson said the Barker Inlet project emerged to replace the 50-year-old A Station at the site.

Initially, Barker Inlet was to be gas turbines, but such a choice didn’t stack-up economically. “The faster efficiency of reciprocating engines and its modularity won over gas turbines and so we signed a contract with Wärtsilä in March 2018,” said Anderson. “We expect the project to be finished around November this year.”

Anderson enumerated some of the features of the gas engines being employed. “You can get pure gas, pure diesel or diesel and gas engines.

It’s fast-start from stop to full load in five minutes when it’s warm,” he explained. “Where I come, from the Torrens Island station, it would take 16 hours if it was cold; these ones are about 15 minutes if they’re cold, so they are very flexible and quick. When they’re hot, after 90 seconds from a start, the signal is synchronised and then another it takes another three and a half minutes before they’re a full load. They have high efficiency at eight gigajoules per megawatt-hour.”

Each engine can produce 10 MW a minute; 12 of them can produce 120 MW a minute. “For a thermal plant that’s unheard of in Australia or anywhere,” said Anderson.

“Essentially, it can go from minimum load to full load in a minute and a half. With starting and stopping with thermal plant (either gas turbines or steam turbines), when you start it, you use up life of the components.

But with a gas engine, you don’t, so there’s no penalty – you can start and stop it as many times a day as you like, and it doesn’t affect the overall overhaul interval.”

Anderson said the gas engines required lower costs for maintenance than gas turbines and a better heat rate. “For our business case, it was

INDUSTRIAL GAS ENGINES

about a twenty five percent capacity factor, which means if you ran all the engines all the time every day of the year it’s hundred percent at full load.

But we expect to run it for about 25 per cent of the year in load terms and about every four thousand hours we do a minor service that takes about five days; and then every 18,000 hours, every five to nine years, we’d do a major overhaul depending on how we run it,” said Anderson.

Anderson said that his team has just about finished the 275 kV switch gear, and would soon installing the step-up transformer. “They’re in place and we’ve just got to now start holding all the insulators on,” he said.

“They finished arriving last week and we’ve just started getting ready to lay the 275 cable, which going to be underground and goes into the gas insulated switchgear switch room, before it goes across the road into an existing B Station. Lots of mechanical pipe work and cables are being joined together at the moment.”

The third and last speaker was

“The faster efficiency of reciprocating engines and its modularity won over gas turbines and so we signed a contract with Wärtsilä in March 2018.

We expect the project to be finished around November this year.”

Andrew Lo, the industrial lubricants product technical adviser lead for Asia-Pacific at ExxonMobil in Singapore. Lo has held a variety of technical and marketing roles in his 32-year career with the company.

Currently, he and his team oversee the execution of global lubricants technology strategy throughout the Asia Pacific region.

Lo explained the application

of engine oil lubricant as part of gas engine maintenance programs.

“Gas engines are really versatile and flexible and can be used in different applications, but one of the maintenance programs is that you need to run the Used Oil Analysis regularly,” said Lo. He detailed several potential benefits of the analysis, such as improving equipment reliability and the productivity of gas engines. “You want to know if parts or equipment are going to malfunction before it happens. So, the Used Oil Analysis is very important – it’s like a blood test for your gas engine that so you know whether something is not right before it happens,” said Lo. “Then, you can prevent the expensive replacement of parts within the engine. Also, if you run this regularly you will know what the optimum oil during in the flow of your oil is, so you can actually not dispose of it prematurely – all this will add up to your total cost of ownership of running gas engines.”

Lo indicated that performance

parameters for a gas engine oil include energy efficiency, oxidation control, nitrogen control, additive retention, viscosity control, and deposit control. He then went on to detail several of the challenges in designing gas engine oil for different applications. For instance, he said, gas engine advancement was leading to a demand for more power alongside more efficiency.

“We started a program using a synthetic base oil as the base and a whole host of additives to see whether it can get some electricity generated from the same engine,” he said. “We validated that, at least compared to normal SAE 40 mineral grey gas engine oil, this 30 SAE oil (synthetic product) can achieve approximately 1.5 per cent energy efficiency.

“Don’t look at it as insignificant: if your engine is running 24/7 full load, this can be a substantial savings of your power generator. So, this case tells us that by just using a special formulation, we can achieve energy efficiency.” PACE

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INDUSTRY 4.0

The Total take on Industry 4.0 Construction companies that understand the requirements of industrial automation are few and far between. Total Construction’s James Bolton and Rob Blythman sit down with PACE to discuss how the company’s expertise extends across the advanced industrial sector.

I

ndustry 4.0 – it is the concept on every manufacturer’s lips.

The potential of advanced technologies and techniques to boost efficiencies, eliminate waste, reduce downtime, to enable flexibility and responsiveness in competitive domestic and global markets is tempting companies across Australia to revamp their systems.

Small-to-medium-sized (SME) manufacturers, also, are noticing that the Industry 4.0 cost-curve, which once made it prohibitive and only affordable by large companies, has greatly reduced in recent years. This, along with the prospect of government grants for adopting productivity-enhancing technology, is enabling smaller players to get involved.

But getting on board with the Industry 4.0 wave also frequently requires more than just purchasing sensors or advanced robotics. Facilities and plant, too, need to be able to deliver the automated solutions that their operators require.

Total Construction has for many years been a name associated with the food and beverage and energy sectors.

But, according to James Bolton, Total Construction’s Energy & Infrastructure Division National Manager, the company is keen to put out the message that they have the experience and skills to build the facilities SMEs require to join the fourth industrial revolution.

“At Total Construction, we are able to deliver projects from concept to completion – from start to finish.

Industry 4.0 is all about integrated solutions. We develop solutions that take into account the whole process,” Bolton said.

Total Construction is developing an Engineering Construction Group, or ECG. The ECG will consolidate the company’s engineering expertise that it has developed in the food and beverage and energy sectors and offer its solution

Total Construction substation works for the Sydney Light Rail project. to the broader industrial market.

“We’re not just going to put a shed over your operations – we’re providing a more total solution with the knowledge we have derived from working with industries that require highly detailed, highly engineered design specifications,” said Bolton.

“The ECG will focus on highly bespoke, heavily designed engineering solutions. What sets us apart is that we’re working in areas that require specialist skill sets.”

Indeed, firms requiring advanced automation processes, require highly technical and customised solutions to make sure they work effectively. “You need to be able to deal with a lot of unknowns. Industry 4.0 is a pioneering space, and construction companies,

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working with clients that are advancing into this space, need to think outside the norm,” said Bolton.

Branching out

While Total Construction has had vast experience in the food and beverage manufacturing sector, and the renewable energy sector, the company has never really been constrained within these sectors, possessing skills that are applicable to all industrial construction work that involves highly specialised, heavily engineered projects.

“Automation is a highly specialised language, which is not always easily communicated in the construction space. We not only have an understanding of that language and, if you like, its different dialects, but

we also possess the practical skills to carry out building projects. What we’re about is translating the language of automation into a feasible and implementable solution to a client’s needs.”

Rob Blythman, business development manager at Total Construction, agreed. “If you look at the projects we have worked on – the Central Thermal Plant, for instance, at Central Park in Broadway Sydney – and if you look at our entire list of projects, they are all heavily engineered projects.

And that, really, is our target market.

We don’t want to just build boxes, we are focussed on the bespoke industrial engineering space,” said Blythman.

“We’re often known as a builder of food and beverage manufacturing

INDUSTRY 4.0

facilities, or of energy facilities. But our capabilities in these areas, because they are already projects involving highly designed and highly specialised engineering works, actually mean we have the capabilities to design and build projects across the advanced industrial sector,” said Blythman.

In other words, with the ECG, Total Construction is providing the knowhow of Industry 4.0 and how it integrates into building projects, providing clients with their specialised requirements, offering them the ability to translate those requirements into a practical construction project that is achievable and understandable.

“That ability is really important to have within the construction industry.

It makes us different. A tradesman will look at you and say, ‘Industry 4.0?

What is that? It’s not on the drawings,’” Blythman explained. “They might be able to install the cabling, but they might not be able to comprehend what impacts it will have on an operation if attention is not given to the precise location and installation practices used.”

The importance of being upfront

Also, on the other hand, a company that goes to specialised engineering consultants can end up with costs blowing out. “The more detail you need, the more it costs. You can end up with engineering builds that are not fully designed because companies can only spend so much with costly design engineering firms. It used to be the case that you would have 80-90 per cent of the project designed before costing takes place. These days, it is down to 50-70 per cent. If something is missing in the design at costing time, the client ends up paying more, as the builder will simply say it was not outlined in the design specifications,” said Blythman.

“A manufacturer just wants to have their building built so that it works and is completed to its specifications without have their costs blowing out.

By ensuring the remaining 30-40 design is captured prior to costing, we provide the client the confidence that their project is priced correctly and meets their operational requirements as intended.”

Working closely with clients, Total Construction provides provisional sums in its pricings. “We say, ‘Look, we don’t know if you need to upgrade your

Total Construction’s Engineering Construction Group will focus on providing industry with highly bespoke, heavily designed engineering solutions. power yet until the design is completed – it is a known unknown – but we’ll include an estimated provisional sum for the power upgrade so that the client understands what they are getting into from a holistic position. It is important to be upfront. A lot of builders won’t do that – they will just exclude those costings, as they are not on the scope of works, allowing projects to frequently blow out beyond budget when they are well advanced.”

Getting it right

For those looking towards innovation, as well, Total Construction won’t leave them without making sure

the basics are in working order. For instance, a large printing business that is implementing a full Industry 4.0 solution across its operations to track material wastage and boost efficiencies will frequently require other work to be done in their facilities to accommodate those changes. “We’re the right company to not only provide them with the building solutions that may be required to implement Industry 4.0, but to incorporate other changes as well – extending the storage area, changing the wall placements for cabling & new equipment, and taking the opportunity to change the process flows,” said Bolton.

Total Construction is providing the knowhow of Industry 4.0 and how it integrates into building projects, providing clients with facilities geared towards advanced industrial processes.

Integration is precisely what is needed when it comes to Industry 4.0. A client who wants to install a monitoring system into their facility might also need to upgrade other aspects to bring their factory up to a modern standard.

“The client needs a solution and we can provide the plan to get them there. And that’s what Total has done in the past. It is important for us to have people who have operational experience as well. That’s where Tony Tate, our general manager, came from. And that is the kind of skill sets, understanding and competence that we provide. We know what works and what doesn’t work,” said Blythman.

“We’ll do the design work, we’ll do the costings, and then we’ll do the build. A lot of builders will just do the costing and the building and go to an expensive engineering consultancy company for the design work. But if you don’t want to spend half a million dollars on design, come to us. If you have specialised, engineering requirements, focussed on automation, we’re your go to company,” Blythman said.

“Companies who are involved in heavily process-oriented operations want to be able to talk to someone who understands the process flows and the bespoke services that are required to make their facility function properly. That’s what our experience gives us – that knowledge to provide the total solution.” PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 25

PROCESS AUTOMATION

The taste of sweet success The need for an all-in-one solution for automation tasks comes from a single source, SEW Eurodrive’s MOVI-C covers complex motion control applications helping a confectionary machine achieve optimum results.

W

hen a candy manufacturer in the United States needed a specific machine to manufacture soft-gummy candies they turned to JH Tester, who have been providing machine control solutions for over 10 years to the candy manufacturer.

Located in the western suburbs of Sydney, JH Tester Industrial Automation has been in operation

for over 35 years. Family-owned and operated, the company was started in 1980 by John Tester, providing technical service and support to the textile industry. Over 20 years ago, JH Tester transitioned its focus to the design and manufacture of automated systems for a variety of sectors, including manufacturing, food and beverage, building, mining, infrastructure, and water processing.

“Our specific strength is motion

The MOVISUITE software package offers a powerful but flexible programming package.

26 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

and motion control – anything that has servo controls is our sweet spot,” Tester said. “And, we also have strengths in PLCs and HMIs. We pride ourselves on providing innovative simple automation solutions to often complex challenges in the manufacturing sector.”

Four modules – one solution Designed and built in Australia, the confectionary machine features 18 MOVI-C Movidrive Modular axis

controlled by the SEW Eurodrive MOVI-C Controller motion platform.

“We’ve had a very close relationship with SEW ever since they entered the variable speed drive (VSD) market in Australia – around 30 years ago. The quality and reliability of their products and services make them an obvious choice for us,” said Tester.

The MOVISUITE software package offers a powerful but flexible programming package that provides

PROCESS AUTOMATION

planning, commissioning, operation and diagnostics software, electronic control and monitoring devices, mechanical drives and gearmotors in an all-in-one solution. All components can be fully integrated into most automation concepts, fieldbus topologies and network standards.

The MOVI-C CONTROLLER motion platform receives setpoints for single-axis or coordinated motions, and determines the motion path for the connected application axis, thereby taking care of tasks such as phase-synchronous operation, electronic cam function or kinematics.

Predefined software modules are used to implement the motion control drive function quickly and reliably with the aid of graphical editors.

Over 50 kinematic models provide for a broad range of mechanical configurations already being covered.

Data is stored via a data exchange function on a memory card in the MOVI-C controller.

All drive functions of the motion control topology are available in the module automation topology.

In addition to the graphical editors for the drive functions, automation tasks associated with the higherlevel master controller can also be implemented in part or in full in a straightforward and flexible approach using the programming system in the MOVI-C controller.

“The all-in-one integrated features of the MOVI-C motion package made it an obvious choice for the project,” Tester said.

“Because it is a highly integrated solution, the MOVI-C was perfectly suited for this specific confection machine application, the heart of which was the motion platform that our internal software design engineer developed.

“The MOVI-C is a neat package – it is a compact practical solution,” said Tester. “Because of the MOVIDRIVE Modular dual axis control mounted in one hardware platform, you don’t need to occupy vast cabinet space to house it, Moreover, it reduces the switch gear and auxiliary components required.”

And, he said, it is also highly energy efficient. “It shares a common powerbase, which means that if any axis is in re-generation, or generating power, I can actually use that power by another axis.” This means that if one

A highly integrated solution, the MOVI-C was perfectly suited for JH Tester’s confection machine application.

axis is slowing down or putting power back into the DC bus, other axes can utilise that power. With effective project planning, this it is possible to have a smaller power section than the collective sum of the control axis, if all axes are not motoring simultaneously, offering a significant savings from an OEM perspective.

Aside from the smarter power solutions, and compact design platform, the MOVI- Movidrive Modular also presented performance enhancements with motor resolution of 65,536ppr which has proven to offer exceptional motor performance.

Another important aspect for implementing this hardware was the integrated safe circuit with level PLe performance.

The simplicity of the MOVI-C MOVISUITE software package allowed easy integration for the entire hardware package. “It also has only one platform to program for the 18 axis – it uses a common master virtual encoder to coordinate many axis, making it highly-coordinated.” said Tester. “The end product, in this example the confection machine, is therefore highly user-friendly and meets our standard for creating simple solutions to complex challenges.”

“High rates of productivity can be achieved with the application of the MOVI-C”, Tester said, with up

to 2.5 tonnes of candy per hour able to be produced by the confection machine. The centrally-coordinating, multiple electronics cam curves enable multiple axis synchronisation for a virtual axis. “Because it is a highly integrated automated solution, we have very precise cam arrangements.

While, normally, you’ll see clients using mechanical cams, we are using electronic cams to more effectively tie axis together,” Tester said.

“And the cams can be changed on-the-fly, which allows configuration of the machine while it is actually working. It means that we can change and modify the cam while the motor is running, modify the time unit of the machine and modify the lathe profile of the pumps during operation. These things are ordinarily very difficult to do while a machine is in motion. So on-the-fly updating of cams is a big advantage in this package.”

If there are issues with the drive, they can be swapped for others, while the SEW MOVI-C controller can download the parameters in the drive and reconfigure a drive with a minimum of disturbance. “This kind of flexibility eliminates downtime.

You don’t have to stop the machine to load up a cam profile,” Tester said.

“And this, once again, creates higher productivity and higher efficiency

in all sorts of ways.”

Using the latest technology integrated into the MOVI-C product range has provided many advantages for JH Tester. “We were ahead of the market using such innovative new technologies. We have had a close relationship with SEW for a long time now, and they’re a great company to work with,” Tester said.

“As we develop new solutions with their products, we are now piloting many advanced and cuttingedge industrial automation solutions with SEW. So, it is a very fruitful relationship that works very well for both of us.”

The MOVI-C’s Ethernet connectivity also means that JH Tester can also deliver high-level after sales support with remote access. “We remotely monitor the machine and make sure it is functioning efficiently and as designed for purpose.”

Indeed, customer service and support on both a local and international level is something that JH Tester prides itself in providing to the manufacturing sector. “We reduce complexity in what can be very complex systems; we’ve simplified the cabinets; we provide high speed communications on the motion platform. The resultant benefits are simplicity and power,” said Tester.

“And, using the MOVI-C, it is very configurable for the end client: it is a stable, reliable, powerful platform that is energy efficient, that doesn’t stop when we change cams, that gives you real-time statistics on what it is doing, as well as real-time power consumption and real-position monitoring of every axis. SEW use ‘smart’ IoT enabled-encoders, so positional data is retained during a power cycle”, Tester said.

According to Darren Klonowski, National Product Manager at SEW Eurodrive the new innovative MOVI-C Automation System is a game changer. “MOVI-C is the complete solution for your automation tasks,” said Klonowski. “With the four modules, MOVISUITE engineering software, MOVI-C controller technology, compact or modular inverter technology and centralised or decentralised drive technology, SEW Eurodrive provides a comprehensive modular automation solution from a single source.” PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 27

2019

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COMMENT

Helping to put you in Control

LogBox Connect WiFi

Getting involved with industry associations IICA generated interest in instrumentation and automation during the recent Griffith Technology Expo and celebrated its annual Christmas in July. IICA NSW chairman Peter Veron writes.

S

everal times a year the Sydney branch of the IICA conducts Technology Expos around the state which provide a unique opportunity to see the newest and cuttingedge innovations in the Engineering field and the ever-changing Technology in the instrumentation, control and automation industry.

The most recent Technology Expo was held in Griffith, a regional town in the Riverina which has strong agriculture, beverage and food manufacturing. Held at the Griffith Exies Club, there were over 50 suppliers and manufacturers of process instrumentation who were available to show and discuss how their equipment can improve processes, increase productivity or help reduce costs.

The community of Griffith always welcomes the bi-annual Expo as it generates increased activities in the region, which benefit both locals and travellers.

The IICA is also held its annual Christmas in July at Athol Hall Mosman. It was be a great opportunity to network in an informal environment between all aspects of the manufacturing industry.

This year’s special guest was Michael Sharpe the NSW State director of the Advanced Manufacturing Growth Centre Ltd (AMGC). AMGC is an industry-led, not-for-profit organisation which supports the development of a world-leading advanced manufacturing industry in Australia.

Michael shared some insightful developments, which all present were very interested to hear.

The last NSW Technology Expo this year will be the Sydney Expo to be held at Rosehill Gardens Grand Pavilion, a premium venue with over 60 exhibitors already booked in on 30th October. This

LogBox Wi-Fi is an IoT device with integrated data logger and Wi-Fi connectivity. It has three universal analog inputs one digital input and an alarm output.

SKU: NOD-012 Price: $499.95 ea + GST

LogBox Connect 3G with GPS The LogBox 3G is an IoT device with integrated data logger and GPS and 3G / 2G connectivity.

SKU: NOD-0111 Price: $899.95 ea + GST

N1500 Process Indicator

Five digit universal process indicator accepts thermocouples, Pt100, 4 to 20 mA, 50 mV and 10 V signals.

Analog retransmission and 2 Alarm Relays. 24 VDC Powered.

SKU: IPI-104 Price: $269.00 ea + GST

Analog Isolated Transmitter Ultra Slim Analog Isolated Transmitter 0 to 5A DC In, selectable current or voltage output. DIP switch allows selection of different outputs 0-5V,0-10V, 0-20mA or 4-20mA. SKU: AXB-125 Price: $189.00 ea + GST

Split core current transducer IICA NSW chairman, Peter Veron. will be an opportunity for engineers, electricians and instrumentation technicians to talk to the experts in the field and get advice on the latest instrumentation available for process control.

IICA Technology Expos are a one-stop shop, featuring many companies showcasing their products or services related to the Instrumentation, Control and Automation Industry, over a drink and light refreshments in a friendly and relaxed environment.

The event is free to attend and a great insight of current available technology.

For a list of all the events the IICA organise around Australia and membership details please refer to their website: www.iica.org.au/events for more details and a complete list of their current CIP members. PACE

Over 50 suppliers and manufacturers of process instrumentation attended the IICA’s Tech Expo in Griffith.

Split core hall effect current transducer presents a 4 to 20 mA DC signal representing the DC current flowing through a primary conductor. 0 to 200 A primary DC current range.

SKU: WES-063 Price: $119.95 ea + GST

Pump Seal Leak Relay

pump seal leak monitor relay/water leak detection relay & thermistor monitoring relay features detection of water contamination of oil, detection of water leaks from pipes in buildings, isolated probe supply and LED indication, Klixon version.

SKU: NTR-211 Price: $199.00 ea + GST

Remote relay control across a LAN Each TCW122B-RR is an Ethernet based I/O module that has two digital inputs and two relay outputs. Two units can be paired in order to seamlessly send digital IO data to the other paired device.

SKU: TCC-003 Price: $119.50 ea + GST

For Wholesale prices Contact Ocean Controls Ph: (03) 9708 2390 oceancontrols.com.au Prices are subjected to change without notice.

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 29

B E F E A TURED IN

Predictive maintenance is an important part of making sure industrial processes run as smoothly as possible. Advances in sensor technology and the Industrial Internet of Things (IIoT) is transforming how quickley and effectively maintenance is carried out. Getting informed about what is happening next at the frontier of these developments will be crucial to those working in process control. The October/November feature of PACE magazine focusses on how predictive maintenance is reducing down-time and boosting productivity across a variety of industrial sectors.

IF YOU’RE INTERESTED IN TAKING PART IN THE NEXT EDITION OF PACE, contact Danilo Cortucci at Danilo.Cortucci@primecreative.com.au

DIGITAL CONNECTIVITY

Securing the supply of energy and data Treotham Automation presents two new igus products that meet the heavy-duty cabling demands of industrial settings.

T

he new igus E4Q energy chain is a lightweight igus e-chain for unsupported lengths and long travels. The first prototype was presented by igus at the Hannover Messe 2019.

The chain links of the e-chain have a smooth, contoured design and a completely new crossbar concept with locking straps for weight reduction.

These ensure that the new series can be opened and closed in seconds without tools. The energy chain has been specifically developed for the special requirements of unsupported lengths and long travels.

High unsupported lengths and long travels with large fill weight create extreme stress on energy chains. The igus developers have designed the E4Q e-chain intended for such application scenarios. Based on the robust energy chain standard E4.1 from igus, the new series brings along a long service life and a high degree of modularity. In order to optimise material and therefore the weight of the energy chain, shapes The E4Q e-chain has been designed for the special requirements of unsupported lengths and long travels.

inspired by nature are used.

The smooth, contoured design can be found on the outside of the chain links as well as on the stop-dogs.

Despite material recesses, the new development has a high strength and stability comparable to the E4.1 series.

Tool-free and quick installation with new crossbars

Another special feature of the E4Q are the crossbars. These can be opened and closed completely without tools. On the top of the crossbar, there are two hollows for the fingers, by which the locking hooks can be easily pulled up.

Unlocked on both sides, the crossbar can be removed with little effort. This allows the easy opening and closing of the chain even in a guide trough and accelerates the filling of the e-chain by up to 40 percent. Another advantage: The new crossbar has significantly higher pull-out forces than its counterparts in the locked state thanks to its innovative type.

Optionally with new additional noise dampening

Due to the special design of the e-chain, this is very quiet in the movement. However, if the user desires additional noise reduction, igus has integrated an optional system in the inner horizontal stop-dog for the E4Q. These are two connected balls that dampen the impact during the radius and extension stop. The balls are made of a new noise-optimised and soft material that further reduces the sound level without restricting the stability of the stop-dogs.

Energy supply in all directions

Also available from Treotham is the new igus e-spool that can up 21 metres of cables and hoses safely without a motor.

Whether at lofty heights, flat on the ground or in depth, with the e-spool – the slip-ring-free cable drum – Treotham offers an energy supply for different application scenarios.

The compact, spring-driven system can safely guide energy, media or fibre optic data cables. To enable users to access the energy chain system even for longer lengths, igus has developed a new standard. And with an optimised design, the e-spool can now extend cables and hoses up to 21 metres without the need of a motor.

In stage technology, on oil platforms or in process cranes, the rollable e-spool is used wherever cables have to be moved safely and in the tightest of spaces. The compact igus energy chain system from Treotham is an alternative to the classic cable drum, but with two major differences: the e-spool is the only solution that can carry not only energy, but also all media such as data, compressed air and liquids.

Because, it connects two different

energy supply systems in one. A standard e-chain, which is guided by a guide roller, always ensures with an integrated retaining spring the correct length and tension of the e-chain system. An igus twisterband is responsible for the rotational movements.

This special structure makes movements in every direction possible.

Another difference would be how the e-spool does not need an expensive slip ring. This means that the most diverse cables can be continuously connected in a confined space in a system, and also be replaced or added at any time. To help users to fall back on the practical energy chain solution for longer travels, igus has developed a new e-spool standard for 21 metres.

Optimised structure for more filling and carrying capacity

The new e-spool has evolved from customer requirements and experience of recent years and covers the gap between the spring-driven standard e-spool for up to 14 metres extension length and the motorised e-spool for large projects, for example in the offshore sector or in opera houses.

The new energy chain system was equipped with a larger twisterband for a higher filling.

To compensate for the payload and extension length, the new structure of the e-spool provides more bracing, a more stable all-enclosing body and a reinforced floor plate as a retraction safeguard.

In order to withstand the higher forces, the developers also opted for an optimised mechanism for adjusting the spring force. The new e-spool standard is available either as a springdriven version with 2 HD springs or as a motor-driven version with a built-in stationary motor. PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 31

CLOUD COMPUTING

Myths and facts about cloud systems Fabio Coelho de Souza Silva of Novus Automation provides insights into the major features of cloud computing in industrial settings.

C

loud computing technologies, widely known as “cloud�, are already a consolidated reality in the market. It is undeniable that this technology is here to stay and change the way the IT sector gets related to companies and organisations. To cut a long story short, cloud computing is related to an infinitely available and flexible computing capacity. This way, hardware and network infrastructure is seen by users as a service where they pay only for what is effectively used. Flexibility and scalability are keywords of this concept, which allow computing resources, maintenance costs and application scalability optimised, among other benefits.

And how important is cloud computing in the context of Industry 4.0, Internet of Things (IoT) and process supervision? Well, this technology has a fundamental role by turning possible and easy the implementation and scalability of systems for data analysis and storage.

That is what makes possible to remotely access information and control devices, making easier to share data and enhancing collaboration between departments of a company.

Many people still keep prejudices that keep them from embracing this technology in business world, despite using it in a daily basis in their private life. The objective of this article is to clarify some things and point out what is myth and what is fact regarding this technology. Hopefully, this will help your decision of adopting cloud supervision systems to be based on solid and clear criteria.

your process will travel and will be stored outside of your company IT infrastructure. But is this a problem?

Most cloud-based s ervices follow a series of international security standards and good practices, with certifications that assure platform performance and security. Following international standards for protecting

Is my data secure outside my company?

Speaking of cloud supervision systems usually means that data of

32 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

your data makes it, for the most part, more secure on the cloud than it is in your local network and storage system, as a local network can be more easily breached.

Another point of concern is the protocols used for transmitting this data. As many industrial communication protocols have

a security layer and many cloud systems do not allow unsecure communication, this should not be a major concern.

Local applications are more likely to have problems caused by vulnerabilities in the user systems. If a computer gets infected, a malware can compromise tool security policies

CLOUD COMPUTING

to get or modify private information.

This does not happen in cloud applications, since all command processing is done in the data centre.

Is the cloud supervision system information I see on my computer screen real time?

When communication media like 3G, 4G or Wi-Fi are used to bring data from devices to our system, either local or cloud-based, we need to be aware that the temperature information displayed on the computer screen is usually not up to date with the current value measured by the sensor. For instance, the temperature value was acquired, and it takes seconds, sometimes minutes, to travel through the communication media chosen and finally be displayed on the user screen. So, when talking

about online supervision systems, we need to consider parameters like communication media, network latency and service availability to understand why online information are not as “online” as we might think.

Novus data loggers, like FieldLogger and LogBox Connect family, send data to the cloud with a timestamp to record the exact moment that data was read from the sensor. This way, users will know the time instant of the data displayed, which eliminates errors due to communication delays or failures.

Is the data saved in my data logger memory identical to the data in my Cloud system?

Data in a supervisory system can be presented in two ways: The first way is with the data linked to the moment with reaches the cloud system, when the temperature value is read by the device and then sends to the supervisory system, for example.

When receiving this data, the cloud system associates the receiving moment with the temperature information, being recorded this way.

The second way is when the device sends, along with the temperature value, the time at with that value was read from the sensor – that is, the timestamp related with the temperature data from the origin in the measurement device.

As previously mentioned, the Novus data loggers that send data to Novus cloud always send them already linked with a time or a timestamp. In this way, the existing data in the Novus cloud database is identical to the data that is in the device memory.

How much does it cost to have a supervisory system in the cloud?

In the cloud, instead of the hiring traditional methods used for local systems, the payment for the resources access is made on demand. Such models are known as SaaS (software as a service) IaaS (infrastructure as a service) and PaaS (platform as a service).

Currently, there are several types of cloud supervisory systems in the market: some for more dedicated

Novus data loggers, like FieldLogger and LogBox Connect family, send data to the cloud with a timestamp to record the exact moment that data was read from the sensor.

“Most cloud-based services follow a series of international security standards and good practices, with certifications that assure platform performance and security.” applications and others with widest terms of functionality. Most of the time, they require specific implementations to leave the system as the client wants and that can generate additional costs. As the number of users or functions is changed, the value of the subscription paid to the service provider is automatically changed, adapting the supply to the demand for processing, connection and storage.

Unlike local systems, where this equilibrium is due to a prediction that managers must make for the future; in the cloud, the company never spends more or less than the ideal.

Novus offers Novus Cloud as a cloud monitoring tool. This service permits cloud monitoring of up to 100 devices in a single account, as well as providing access to dashboards with preconfigured widgets to view data on registered devices and the possibility to

creating custom dashboards when using on-screen widgets and showing the information that most interests users.

Using NXperience software, it is possible to download existing data in Novus Cloud to create reports and export data to several formats, among other features. This package has no cost to the client. It is possible for the client to purchase packages with more customizable dashboards, SMS packages and scripts to send notifications, for example.

Why would I change my local supervisory system by a cloud system?

In the most of time, maintaining a cloud supervisory system is safer and cheaper, and has infinite scalability.

Yet, it is a solution that needs constantly Wi-Fi connection and, most of time, industrial converters protocols drivers to send the data to the cloud. Local solutions will have faster responses to critical processes, which can be crucial for companies that work with sensitive data or with short answers times.

With this overview, we can say that is always important to evaluate the situation. The important thing to know is that, today, a cloud system cannot be simply rejected by concepts that we had in the past, such as security problems and high implementation costs.

Ocean Controls is the Australian Distributor for Novus Automation. PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 33

Discovering your own strengths in industry While some may have the image of a dream job set in their heads and take steps towards pursuing that vision, for others, careers can be a journey of discovery. PACE talks to Rockwell Automation’s Jasmin Perry about her career in process control.

F

ollowing the paths that open up along their twists and unexpected turns can lead to outcomes more rewarding than one could imagine. For Jasmin Perry, a job in the industrial automation industry opened up after a career shift.

“I had an interest in the automation industry, so I took an administrative role at an industrial automation and process control instrumentation company.”

Being immersed in the world of automation and process control for the first time, Perry discovered a field that rewarded her interest in customer service, while also having the technical complexity to continue to challenge her. Seeing the potential for herself within the sector, when a chance for advancement came up, Perry seized the opportunity.

“I was fascinated with the complexity of the industry, so when a technical support role opened up, I put my hand up and my boss saw I had a natural knack for it,” said Perry Moving from the position of sales administrator to sales support engineer, Perry approached the role and the requirements having had a background in the highly-customer focussed industry of event management. Perry saw the parallels in the outcomeoriented nature of the position.

“For me, it was that satisfaction of being able to be part of something whereby I’m solving someone’s problem. They’ve got an application that they need a solution for and I’m putting that solution together for them,” said Perry.

Perry was supported to study and gain knowledge of the technical side of the process and automation control field. Perry completed her Certificate in

Instrumentation, Automation & Process Control while working, yet at the same time was acquiring in-depth knowledge through being hands-on with customers in their factories and facilities.

“A lot of learning for me has been out on the field,” noted Perry.

“You’re learning something every day; the average inquiry comes along and

Jasmin Perry was nominated as a finalist in Rising Star category at the 2019 Women in Industry Awards.

34 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

then you are applying what you learnt the next time it comes around.”

The next step was moving to senior sales support engineer, which involved leading the internal sales team. Drawing on her experience and strengths, Perry trained and mentored other members of the sales team. In addition, Perry streamlined internal

processes for improved efficiency while implementing SAP training across Australia and New Zealand.

As Perry was developing her skills and expertise in the industry, others began to take notice.

“I was with the industrial automation and process control instrumentation company for about six years and then Rockwell Automation tapped me on the shoulder. They were looking for someone to come in that they could groom into the position and I just happened to fit what they were looking for.”

New ways of approaching sales began to open up. With the support of Rockwell Automation’s training programs and by adopting their disciplined sales process in her new role of key account manager, Perry brought her passion for customer relationships and solutions to the fore.

“My role for me is more than just sales; I prefer to be seen as a consultant and an advisor, not just someone that’s selling something.

That’s always been my mentality, and that comes from my customer service background, where I’ve been helping people,” said Perry.

At Rockwell Automation, Perry has been focussed on connecting with the customers of Rockwell Automation based in food and beverage manufacturing and original equipment manufacturers (OEM).

In a field such as this, where tailored solutions and precision is key, Perry has been able to work with customers to radically improve processes.

“I’ve got some clients where I’ve taken them from having minimal formal processes or migration strategies in place, to developing a detailed plan and introducing

Perry has been focussing on connecting with Rockwell Automation customers based in food and beverage and original equipment manufacturing.

Rockwell’s solutions and services to make their plant more efficient and profitable,” said Perry Working with clients on these solutions and services, Perry returned to her philosophy of being a consultant and advisor.

“I think, traditionally, a lot of people would see sales people as just ‘sales people’, but I don’t believe that’s true, especially with industrial automation. We’re not just selling boxes, we are solutions providers,” said Perry.

“We’re not just here to sell them something and then say ‘See you later’. We have an obligation and a responsibility to support our client in their digitisation journey, from being completely inefficient and manual, all the way through to becoming a profitable automated site.”

Earlier this year, Perry was

nominated as a finalist for the Rising Star award at the 2019 Women in Industry Awards. For Perry, this accolade brought home the journey that she had been on from her first role to where she was now, and how she’s had to put herself into situations where she had to be confident in her abilities.

“It was such an honour to be nominated because it’s a challenging industry and over time I’ve learnt to not be afraid to speak up and to have a voice,” said Perry.

Being nominated for this award reinforced the successful work that Perry had done since she had initially put her hand up to move up in her role.

“I feel lucky to be working for a company that has allowed me to continually grow and expand my skills, so to be recognised on how hard I’ve worked and all the things

I’ve achieved so far, it was a really big deal for me. It gave me that reassurance that I’m doing a good job,” said Perry.

Putting the skills and knowledge that Perry has learnt throughout her career into practice has led to a few large opportunities for herself and for Rockwell Automation. Perry recalled working on a large client that Rockwell Automation was trying to develop a corporate relationship with. With Perry’s focus on customer service and disciplined approach to sales, she was able to build strong relationships with key influencers and decision makers. Through these connections, Perry was able to introduce solutions and services from Rockwell Automation, ultimately establishing a national framework agreement which has led to Rockwell Automation being part of the client’s

long-term plan to modernise multiple plants across the country.

During experiences such as this, and in the context of the demanding nature of the process control and automation industry, Perry has had to back herself on her expertise and perspective.

“Just because I might be new to a certain role and that person might have been doing it for five years, that doesn’t make me any less competent than anyone else, because there’s other experiences that you can bring to a role to add value.”

Looking back on her career, Perry highlighted that being confident in her abilities has been what has led her to succeed.

“Don’t ever underestimate yourself,” said Perry. “To succeed, it’s important to be resilient, confident and continually challenge yourself.” PACE

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 35

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RELY ON AUSTRALIA’S MANUFACTURING, MINING AND INDUSTRIAL HUB 70,000 monthly users can’t be wrong. Find what you’re looking for with over 12,000 business listings and 8,000 specific product listings. Access relevant information and resources, empowering you to make a qualified purchase decision. You can always rely on your industry hub.

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NEW PRODUCTS

Katronic expands product range with innovative flowmeter for gases Katronic is very proud to announce its newest development, the KATflow 180 clamp-on flowmeter for gases. The ATEX-approved KATflow 180 takes non-invasive, clamp-on measurement into new areas with the ability to measure gaseous flow at low pressures and even in metal pipes – something that was previously virtually impossible to achieve.

Clamp-on measurement of gas has, typically, been limited to high pressures, plastic pipes and “ideal” installations. The KATflow 180 gives excellent results right down to atmospheric pressure. In addition, Katronic’s “Lamb wave” technology makes accurate measurement possible even in metal pipes, including steel.

A gaseous medium dampens an ultrasonic signal far more than a liquid, making non-invasive flow measurement of gases far more difficult. The effect reduces as pressure increases, hence the five bar lower pressure limit at which conventional transit time measurements using shear waves can be made. Katronic’s Lamb wave transducers are excited at the resonant frequency of the pipe material, making the pipe wall act as both emitter and receiver of the ultrasonic pulses, multiplying the effective transducer area for a higher signal strength and a better signal/noise ratio.

A stronger signal means that the KATflow 180 is better able to compensate for the attenuation of the gas, and Katronic have developed advanced signal processing techniques to analyse the measured data and deliver an accurate measurement.

The KATflow 180 is able to measure in pipes from 25 mm to 1.5 m diameter, with flow rates of 0.1 m/s to 75 m/s and pressures of 1 bar up to unlimited maximum. It is designed to be capable of being mounted permanently in an ATEX Zone 1 or 2 hazardous area, with a robust housing and non-intrusive programming.

AMS Instrumentation & Calibration Pty Ltd 03 9017 8225 www.ams-ic.com.au

Backplane Systems Technology presents iBASE’S UPC-7210 Industrial Panel PC for retail and catering environments Backplane Systems Technology is excited to present iBASE’s sleek new industrial panel PC, the UPC-7210.

This 21.5” fanless panel PC has been created with smart retail and catering applications in mind, featuring a full range of I/O, a visually appealing design, 7th Gen Intel Core processor, and sealed housing with an IP65-rated front panel. This panel PC is ideal for customerfacing applications, though it can be applied to any range of applications requiring a PC of its calibre.

It features a full flat bezel design and a 1920 x 1080 IPS LCD with projected-capacitive touch screen that allows multi-touch and gesture-touch functionalities. It comes equipped with 4x USB 3.0, 1x USB 2.0, 2x Gigabit Ethernet, an extra HDMI and DP graphics, 24VDC input, and up to 32GB of DDR4 support. Other features include 64GB SSD storage, mPCIe for mSATA, 12VDC input, optional wireless solution, and OS support for Windows 10 and Linux Kernel 4+. With VESA mounting (100 x 100), the UPC-7210 is not just restricted to wall mounting but can also be fitted to a desk mount or placed on a swivel arm.

This visually-appealing panel PC is aimed to enhance customer experiences in retail and catering environments such as convenience stores, department stores, airports, cinemas, and specialty stores.

These high-performance and low-power systems are designed for long-term use and have no problem operating in ambient temperatures of up to 50°C. Key Features: • 21.5” IPS LCD, 1920 x 1080

• Projected-Capacitive Touch Screen with Multi-Touch • IP65 Waterproofed Front Panel • Supports Variety of Processor Platforms (Performance to Entry Level) • Optional Wireless Solution Backplane Systems Technology 02 9457 6400 www.backplane.com.au

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 37

NEW PRODUCTS

ICP DAS’ I-7565M-HS high speed USB to 2-Port CAN Bus converter

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ICP Electronics Australia introduces ICP DAS’ new I-7565M-HS highspeed USB to 2-port CAN bus converter.

The I-7565M-HS is a brand-new high-speed USB-to-CAN converter with two CAN channels. Providing even faster CAN bus communication performance than its I-7565 predecessor, it supports CAN2.0A/2.0B protocol and different baud rates ranging from 5 kbps to 1000 kbps. The most important feature of the I-7565M-HS is its ability to support the user-defined baud rate functionality no matter what that baud rate is.

When the I-7565M-HS is connected to a PC, the PC will automatically load the relevant device driver (hot plug and play). As a result, the I-7565M-HS makes data collection and the processing of CAN bus networks fast and simple for any user. This module is perfect for a range of applications including CAN bus monitoring, building automation, remote data acquisition, environment control and monitoring, laboratory equipment and research, and factory automation.

Key Features: • Compatible with high-speed USB 2.0, ISO 11898-2 Standard •S upports CAN2.0A, CAN2.0B, and CAN Bus message filter configuration • Powered via USB, firmware updates via USB • Programmable CAN Bus baud rate (10kbps~1000kbps) • CAN message timestamps within ±10us Precision • Internal watchdog timer •P WR, CAN Tx/Rx, and CAN status indication LEDs •B uilt-in Dip-Switch to select 120 ohm terminal resister for CAN Bus

•U tility tool for users module setting and CAN Bus communication testing • API Library for user program development ICP Electronics Australia 02 9457 6011 www.icp-australia.com.au

Avoiding mould with igus polymer plain bearings For the building and vehicle technology as well as for the aircraft industry, mould is not only a great annoyance, but also a serious health hazard. To prevent this, it is not only important to use the right ventilation technology, but also to use mould-resistant components. Therefore, igus had its materials tested for mould growth. The result: all plain bearings are resistant to fungi and bacteria.

If mould develops in ventilation systems, the mould spores in closed rooms, vehicles and buildings are permanently distributed in the air and can easily get into the respiratory tract. To avoid this risk, designers rely on machine elements that are resistant to mould. The high-performance plastics from Treotham are such materials. In a laboratory test, seven iglidur materials were tested for the effect of microorganisms in accordance with DIN EN ISA 846 method A. This test examined the resistance of the materials to fungi and bacteria. After all, plastics can be used by microorganisms as a source of food and can be changed by the metabolic products of the bacteria. For the test, the plain bearings were stored in a special culture for four weeks at 29 °C. The result: an alteration was not found on the tested materials, nor was there a case of mildew.

Various possible uses in ventilation technology The mould-resistant, lubrication-free and maintenance-free plain bearings are used in aircraft seat and arm adjustments and for the storage of onboard kitchen equipment and luggage lockers. In building technology, plain bearings made of iglidur materials can be found, for example, in ventilators and in air damper regulators, which also benefit from the corrosion-free nature of the plastic bearings. Here, the plain bearings also display their insensitivity to dirt. The polymer bearings are easy to clean and resistant to temperature, media and chemicals. Another advantage: The service life of iglidur bearings can be easily determined online with the service life calculator.

38 www.pacetoday.com.au AUGUST/SEPTEMBER 2019

Treotham Automation 1300 65 75 64 www.treotham.com.au

NEW PRODUCTS

Rackmount 4K KVM drawer with built-in USB KVM switch Interworld Electronics has announced the addition of a Rackmount 4K KVM Drawer with built-in 4K HDMI USB KVM Switch to its popular line of KVM Drawers.

The RACKMUX 4K KVM Drawer with built-in 4K HDMI USB KVM Switch combines a rackmount 4Kx2K LCD monitor, keyboard, touchpad mouse and a 4K HDMI USB KVM Switch in a space-saving 1RU industrial strength drawer.

Each RACKMUX-4K17-N-xHD4K consists of a compact, heavyduty tactile keyboard with 17-key numeric keypad; a three-button touchpad mouse; and a forward-folding 17.3” TFT/LCD monitor that supports resolutions to Ultra-HD 4Kx2K 3840x2160 at 30Hz. The LCD screen automatically shuts off when in the closed position.

Torque-friction hinges prevent the monitor from wobbling, springing or slamming shut.

The KVM drawer features an integrated 4-, 8-, or 16-port 4K HDMI USB KVM Switch, which allows a user to control up to 16 Ultra-HD 4Kx2K 30Hz USB computers. Dedicated internal microprocessors emulate keyboard and mouse presence to each attached CPU 100 per cent of the time so all computers boot error-free.

Constructed with rugged steel and a durable powder coat finish, the rackmount drawer is designed to be a one-person installation job. It is adjustable to various rack depths from 24” (610 mm) deep to 40” (1,016 mm) deep. The drawer locks into place when open to prevent it from sliding in and out of the rack.

Interworld Electronics & Computer Industries +613 9593-7555 www.ieci.com.au

New eBook from Mouser and Phoenix Contact highlights secure connections in industrial IoT Mouser Electronics, announces a new eBook in collaboration with Phoenix Contact, offering an in-depth look at connector designs and their importance in the rapidly involving Industrial Internet of Things (IIoT). In Trusted Connection, Trusted Design, experts from Phoenix Contact provide useful guides on PCB design, locking systems, and new connecting technologies, offering readers valuable insights on how to leverage connectors for more reliable performance.

As more devices are folded into IIoT, strong connections will take on additional importance to support the intelligence of smart devices.

The demanding requirements of IoT include both time-tested features and new innovations, from effective latching mechanisms to active circuit indication and shielding to facilitate faster data rates.

The new eBook from Mouser and Phoenix Contact features multiple detailed guides on specific connectors as well as their applications in PCBs and industrial design. Phoenix Contact’s experts offer useful instructions on how to choose the best PCB terminal block, in addition to what common mistakes and design flaws to avoid. The eBook also provides a valuable guide on the use of M12 connectors in industrial facilities, as well as SKEDD direct connection technology.

The Trusted Connection, Trusted Design eBook also highlights relevant products from Phoenix Contact, including the company’s MKDSP95 Series terminal blocks and reliable M12 connectors, industry-leading RF modules and switches. The company’s products, available from Mouser, include UT terminal blocks, board-to-board connectors, and PCB connectors, each offering trusted support for industrial design and IoT applications.

Mouser Electronics +852 3756-4700 www.mouser.com

AUGUST/SEPTEMBER 2019 www.pacetoday.com.au 39

Low-cost level measurement.

Radar sensor for water management.

Reliable level measurement in water treatment facilities, pump stations and rain overflow basins.

Open channel flow measurement and water level monitoring.

VEGAPULS WL S 61 ▪ Measuring range up to 8 m

▪ Can be used outdoors without restriction ▪ Flood-proof IP 68 housing

▪ Operation via Bluetooth with Smartphone, tablet or PC

Further information: www.vega.com/wls61

Phone 1800 817 135