Industrial Factory Automation

A Kuka robot is helping one of the UK's leading bespoke furniture makers to expand its end-to-end manufacturing capabilities by undertaking a variety of finishing operations. The 100kg payload seven-axis KR100 model has been installed in an automated production cell at Jali's factory in Kent to streamline a series of machining tasks on a number of new product lines. It features a versatile end effector for holding the range of tools used in the various finishing processes, which range from cutting apertures for window-shutter hinges to decorative edge profiling of bookcase panels.

Precision Micro has developed LEEF (Laser Evolved Electroforming), a manufacturing process that can produce any volume of intricate and fine-featured metal-encoder discs and strips. The process can meet standard slot counts and bespoke requirements in the same economical fashion. It can achieve apertures of less than 15 microns - with high repeatability and smooth walls with optically sharp edges - without the use of prohibitively expensive glass master tooling. It uses electrodeposition, which, atom by atom, forms burr- and stress-free discs onto a digitally patterned mandrel; these can be either totally flat or multi level. The multi-level process can produce discs and strips that are exceptionally thin in the feature area to facilitate a crisp, well-defined light pulse, while being thicker in other areas to meet mechanical requirements.

A provider of food, beverage and specialty chemical ingredients is using a Chronos BTH seed-bagging system. In summer 2009 the company had a requirement for a seed bagging system, which Chronos BTH supplied within six weeks of the sale. This bagging line incorporated a Chrono-Weigh H17E electronic bagging weigher. Operating on a gross weighing principle, the H17E is a fully automatic bagger with a pneumatically operated bag spout for manual bag-placing and is controlled by the SpeedAC NXT high-accuracy weighing controller. Downstream of the H17E is a transfer conveyor with stitcher, bag kicker and manual palletising conveyor. Chronos BTH engineered the solution then installed and commissioned the simple bagging system in time for the customer to meet its obligations and pack the first batch of product on time. The Chrono-Weigh H17E automatic bagging weigher has a full-loadcell design and is suitable for bagging a range of free-flowing materials into various types of open-mouth bag. Co...

The International Society of Automation (ISA) is to host the 55th Analysis Division Symposium on 26-29 April 2010 at the Astor Crowne Plaza, New Orleans, US. This year's theme, 'Analytical Solutions in a Not So "Big Easy" Economic Environment', covers process analysis topics ranging from methods and applications to compliance, system operation, and maintenance. The event is sponsored by the ISA Analysis Division. Formal published papers, informal reports, short courses, ISA training, speaker sessions, and panel discussions will focus on technology used in industry practice, as well as new technology currently in development. Chemical analysers, validation, system integration, and analytical hardware and software are all featured topics for the conference presentations. The three full conference days of the event offer attendees professional development hours. In addition, the ISA training course, 'Advances in Continuous Emission Monitoring', will offer co...

DTEC has completed a multi-column turnkey project at a chemical plant located on the east coast of the UK. The project focus was on the refurbishment of a stainless-steel process tower with a diameter of approximately three metres, which required a corrosion-resistant weld overlay CrNiMo-3 (Alloy 625) onto a stainless-steel base material. DTEC achieved this without incident, using Vclad Weld Overlay technology. Vclad combines digitally controlled synergic welding technology with multi-directional programmable automation. The result is a high quality and productive weld-overlay process that can be applied to many repair and upgrade scenarios, ranging from replacement of original equipment design materials through to the application of corrosion-resistant alloys. Weld procedures are qualified to both ASME and EN standards, and because DTEC holds a library of typical PQRs, it can react to unknown scopes often found during routine turnaround inspections. Due to the flexibility of the Vcla...

Bluewater Bio International has announced that its Hybacs process is continuing to show high performance in independent pilot trials carried out by Severn Trent Water in the UK and Aqualia in Spain. Both pilot trials are ongoing but at different stages. The collaboration with Severn Trent Water, which began the trial earlier, is now progressing with consideration being given to the potential of a full-scale installation. Results from pilot plants installed at operational sites managed by Severn Trent Water and Aqualia verify that the Hybacs (hybrid bacillus activated sludge) process can remove nutrients from municipal-type wastewaters to comply with European regulations. More specifically, the plans have demonstrated Hybacs' efficacy in removing ammonia, nitrogen and phosphorus (key indicators of nutrient levels) to levels that comply with the general requirements of the sensitive area regulations in the European Union Urban Wastewater Treatment Directive. Severn Trent Water se...

The Applikon Analytical ADI 2040 process analyser from Metrohm is a multipurpose wet chemical analyser designed to offer flexibility and withstand harsh environments. The analyser uses techniques including titration, colorimetry and dynamic standard addition with ion-selective electrodes. The analyser's rugged hardware and the possibility to do automatic calibration and cleaning result in a 99.5 per cent up-time, according to Metrohm. Its versatility allows the incorporation of multiple analyses and multiple sample streams on one analyser, resulting in low cost per analysis/sample. The controller makes it possible to run up to three independent analyses simultaneously. Reagent usage is minimised by using low-volume measuring cells. The ADI 2040 has a modular wet part with 20 uniform positions for a variety of modules and accessories. It can be adapted to almost any application. In the electronic part, the same modular concept is used, so that the I/O cards for control of the wet p...

An Air Control Industries (ACI) Jetblack personnel de-duster has replaced a dangerous compressed air cleaning process at a Steetley Dolomite works. The Whitwell Works of Steetley Dolomite quarries and produces magnesium limestone products for the steel, refractory and agricultural industries. After the limestone is quarried, it is crushed, sized and processed to produce various products for applications such as steel furnace manufacture and repair, steel production, refractory products and agricultural soil improvement. The processing of the limestone to produce these products results in the creation of a lot of dust around the plant, which gets deposited on the overalls of workers on site. To de-dust themselves, although advised frequently not to because of the very real danger that it poses, many of the staff would clean their overalls down with compressed air. Posters about the risks and verbal warnings from the safety leader for compressed air, John Collins, seemed to do little to...

Stratophase has collaborated with the Centre for Process Innovation (CPI) to develop an insertion probe variant of its Spectrosens system. Enabling real-time monitoring of the bioproduction fermentation process, the multi-output Spectrosens insertion probes track compositional changes and monitor temperature in the liquid. Multiple discrete readings can be taken simultaneously at numerous locations, providing more reliable measurements and a reduced chance of false positives. As a result, the entire fermentation process can be precisely monitored to ensure reproducibility and clear determination of the desired end-point. The Spectrosens system sensors can be placed throughout the production process and networked via the control and analysis unit. Using only light at the point of measurement, the sensors are intrinsically safe and spark free, removing any chances of ignition. The insertion probe fits standard ports for dissolved oxygen (DO) and pH probes, enabling ultra-high resolution...

The Formdrill process uses a special carbide tip to drill through thin materials such as sheet metal using friction, removing the need for nuts and bosses. The Formdrill process involves a carbide conical tip (Formdrill) that heats up the material by friction into a super-plastic state, enabling the Formdrill to push through and form the hole and displace the material into a bushing that generally triples the material thickness. This additional wall surface is then threaded, eliminating the need for welded nuts, bosses or inserts. This bushing is also used as support for brazing or as a bearing wall in rotating shaft applications. It can be used on most drill presses, milling machines or CNC systems. The only parts required are a tool holder, a collet and the Formdrill. Each Formdrill will perform from 8,000 to 10,000 cycles in mild steel, a little less in stainless steel, and more in aluminum and copper. This process is claimed to have the ability to reduce costs from 50 per cent ...

SMAC has developed a linear/rotary actuator, the LAR35 series, as a tapping process for a watch manufacturer in Switzerland. The tap diameter is 0.38mm; the part has a diameter of 3mm and is 0.25mm thick. The LAR35 series has a 50mm stroke and is mounted vertically with the shaft looking down. The custom tip is attached to the shaft end of the actuator to hold the tap.The shape of the parts can be varied so that the customer can hold the part to tap manually, while the fixture is being developed. SMAC's patented soft-land capability allows the tool to land on the part gently, move back 0.1mm, start the rotation, press the linear axis with a small force, check any variation on torque on the rotary motor to avoid failure and check the linear position when the tap reaches the required position. The same procedure takes place in reverse. For the SMAC LAR series, linear and rotary are combined in one unit. With all SMAC actuators, force, speed and position are fully programmable.

A team at Precision Micro has developed a process to make Elgiloy, an austenitic super alloy, 'etchable'. Elgiloy is based on cobalt and is an erosion and corrosion-resistant stainless steel. Photo etching is a manufacturing technology that produces intricate, burr free, stress free, high-precision profiles by a process of controlled erosion. On the face of it, Elgiloy and photo etching should be incompatible. This was the case until the process development team at Birmingham-based Precision Micro came up with a process route that the company claims has solved the problem. 'The solution does not just involve a combination of etchant chemicals,' said Bob Crutchley, director. 'A methodology has been developed, whereby a treatment is applied prior to etching and a catalyst is introduced during the etching process itself,' he added. The process utilises standard photo resist materials and chemicals that have no exceptional hazard risk. It is designed to enable engi...

GE Fanuc Intelligent Platforms has released Proficy Process Systems in a 250 I/O size, single-computer offering targeted at smaller applications and OEMs. Proficy Process Systems is a fully-integrated process control system that can provide customers with improved quality and reliability, increased throughput, performance and efficiency and reduced total cost of ownership. The foundation of Proficy Process Systems is a contemporary hardware and software infrastructure that offers the benefits of traditional DCS and PLC/HMI systems, without many of the historic limitations of those approaches. Proficy Systems is also packed with control features including a comprehensive set of function blocks for advanced regulatory control. In addition, user-defined function blocks can be created for the freedom and flexibility to define control algorithms as necessary, which system integrators can lock to protect their intellectual property. Proficy Process Systems supports Foundation Fieldbus, P...

InnoCielo Publisher and its modules make it possible to automate the publishing process, triggered by predefined document lifecycle events or on an ad-hoc basis. BlueCielo ECM Solutions has released InnoCielo Publisher 2008, the latest version of the optional Publisher add-on for the InnoCielo Meridian Enterprise ECM solution. InnoCielo Meridian Enterprise automates the rendering and publishing of engineering content. In the publishing process, engineering documents are rendered into universally readable formats and stored in a target system such as a Windows folder, an FTP site, Microsoft SharePoint, Documentum or InnoCielo Meridian Enterprise itself. InnoCielo Publisher and its modules make it possible to automate the publishing process, triggered by predefined document lifecycle events or on an ad-hoc basis. InnoCielo Publisher is used with InnoCielo Meridian Enterprise by companies such as Areva TandD Systems, Huntsman, Johnson Controls, Pfizer and Siemens in energy/utilities, ma...