MIT ENGINEERS 3D PRINT
THE ELECTROMAGNETS AT THE HEART OF MANY ELECTRONICS
Imagine being able to build an entire dialysis machine using nothing more than a 3D printer.
This could not only reduce costs and eliminate manufacturing waste, but since this machine could be produced outside a factory, people with limited resources or those who live in remote areas may be able to access this medical device more easily.
While multiple hurdles must be overcome to develop electronic devices that are entirely 3D printed, a team at MIT has taken an important step in this direction by demonstrating fully 3D-printed, three-dimensional solenoids.
Solenoids, electromagnets formed by a coil of wire wrapped around a magnetic core, are a fundamental building block of many electronics, from dialysis machines and respirators to washing machines and dishwashers.
The researchers modified a multi-material 3D printer so it could print compact, magnetic-cored solenoids in one step. This eliminates defects that might be introduced during post-assembly processes.
This customised printer, which could utilise higher-performing materials than typical commercial printers, enabled the researchers to produce solenoids that could withstand twice as much electric current and generate a magnetic field that was three times larger than other 3D-printed devices.
In addition to making electronics cheaper on Earth, this printing hardware could be particularly useful in space exploration. For example, instead of shipping replacement electronic parts to a base on Mars, which could take years and cost millions of dollars, one could send a signal containing files for the 3D printer, says Luis Fernando Velásquez-García, a principal research scientist in MIT’s Microsystems Technology Laboratories (MTL).
“There is no reason to make capable hardware in only a few centres of manufacturing when the need is global. Instead of trying to ship hardware all over the world, can we empower people in distant places to make it themselves? Additive manufacturing can play a tremendous role in terms of democratizing these technologies,” adds Velásquez-García,
MIT researchers modified a multi-material 3D printer so it could produce three-dimensional solenoids in one step by layering ultrathin coils of three different materials. It prints a US quarter-sized solenoid as a spiral by layering material around the soft magnetic core, with thicker conductive layers separated by thin insulating layers. IMAGE: Courtesy of researchers.
FIRE AND GAS MAPPING…
IMPROVE HAZARD DETECTION AND WORKPLACE SAFETY
Fire and gas mapping (FGM) is used to improve safety and reduce the effects of flammable gas releases, toxic gas releases and fire hazards found at major hazard facilities.
If you manage or work at locations with fire and gas hazards, fire and gas mapping can be used to accurately design an effective fire and gas detection system to mitigate the specific hazards found at the facility.
Equinox Automation is a specialist instrumentation and control engineering consultancy offering a range of engineering services. The company has experienced engineers that have delivered FGM studies across a broad range of New Zealand industries including offshore facilities, oil and gas production, hydrogen production and storage, process industry, geothermal binary power plants, compressor stations, and industrial ammonia refrigeration plants.
“An effective fire and gas system (FGS) is a final barrier to reducing harm when all other barriers have failed,” says Hardie McLaren, founder/senior engineer at Equinox Automation.
McLaren says that New Plymouth-based Equinox Automation is expert in process industry fire and gas systems and detection technologies.
The main purpose of an FGS found in industrial plants is to detect a hazard early and to reduce the effects of a hazard before it escalates. To achieve this, a FGS should have these primary functions built into the system: detecting and warning people of hazards, activating automatic shutdowns and initiating emergency operating procedures.
“FGM is an engineering process that can be used in the design phase of a project, or as a method to evaluate existing systems. This process involves a range of engineering tasks,” says McLaren.
These could include:
• Reviewing of site fire and gas hazard risks.
• Hazard screening – gas dispersion modelling, fire modelling.
• Fire and gas risk assessments.
• Selecting detector coverage targets to reduce facility hazard risks.
• Developing coverage maps with specialist 3D software.
• Layout optimisation to ensure no blind spots and lowest quantity of detectors.
• Designing coverage verification.
• Optimised gas detector positioning with CFD modeling.
• Developing site detector layout drawings.
• Documenting in a FGM study report with key activities, results, and recommendations.
Historically, fire and gas detection layouts were determined using rule of thumb methods, or by simply drawing circles on a layout drawing. Even though these methods may have reduced engineering costs upfront, they could not provide assurance that the hazard risks had been correctly quantified and mitigated within the design. Something common with these design methods, actual real gas releases are not detected due to design errors in detector quantities and placement.
“With a small investment, using the latest fire and gas mapping techniques will provide assurance that a fire and gas system is designed correctly to detect and mitigate specific fire and gas hazard risks found at a facility.”
According to McLaren, another benefit of a correctly designed FGS, if following IEC Standard IEC-61511 Functional safety – Safety instrumented systems for the process industry sector, the FGS can be used as a risk reduction credit within LOPA risk assessments.
“So, while improving process plant safety, an effective FGS will significantly reduce project costs related to functional safety risk reduction achieved with safety instrumented systems (SIS).
Lead process safety engineer of one local energy utility business was thankful the team at Equinox Automation was on hand to assist: “Their expertise and recommendations will make a significant difference at our facility, and we are grateful for their support”.
McLaren adds that Equinox Automation is committed to helping industries improve workplace safety with “safer and more effective fire and gas system designs to help protect people, assets, and the environment from harm caused by fire and gas hazards”.
For more information phone 0800 4 EQUINOX or visit www.equinoxautomation.co.nz.
Transforming industry – exploring the application of advanced manufacturing in New Zealand.
By Dr Troy Coyle, HERA CEO
Recently, HERA visited Australia with Minister for Small Business and Manufacturing Hon Andrew Bayly and heavy engineering industry representatives to better understand how Australia is responding to the Industry 4.0 revolution.
This visit included a tour of both the University of Wollongong’s Facility for Intelligent Fabrication (FIF) and the $81 million Australian Composite Manufacturing Co-operative Research Centre (ACM CRC). Gaining access to these impressive facilities demonstrated how the use of cutting-edge technology is revolutionising manufacturing in Australia and its potential to do the same in Aotearoa. It was also clear that long-term funding (in the case of the CRC program, which is ten-year funding) and industry-led research are key to successful industry transformation through the adoption of these technologies.
We were also proud to see HERA acknowledged as a key partner in several of the ACM CRC’s projects, including the application of AI to quality systems, circular design of composite materials, technical and scientific barriers for robotics and automation in composite manufacturing, and waste management in the composite industry.
Industry 4.0, also referred to as the fourth Industrial Revolution, is a broad term for new technologies and data such as cloud computing, the Internet of Things (IoT), and artificial intelligence. The future of manufacturing will require widespread adoption of Industry 4.0 technologies to transform how goods are made by optimising processes and driving the potential for unprecedented efficiency and productivity gains.
These advances have been a core focus for HERA to understand in order to drive the transformation of New Zealand’s manufacturing sector and its future readiness. We want to see our sector at the cutting edge of these developments, so we have been focused on developing our facilities and supporting research and services to help our manufacturing and construction sectors understand the potential for uptake.
Knowing how to incorporate these new technologies into business models can be difficult and requires a financial commitment that is not often achievable for businesses with no innovation strategies in play. In driving the adoption of Industry 4.0, it is not so much about focusing on the underlying technologies (although this is very important), but more so, helping our industry understand how these technologies can support their businesses. Having industry come along on this trip as part of the delegation was a great way to achieve this. We were delighted to accompany the Minister in this tour. HERA has long advocated for the need for a Minister of manufacturing. We look forward to working with the Minister in this space and seeing how the manufacturing sector can grow and thrive as one of his portfolio
Engineer salaries increase but short-term challenges and skills crisis looming
Engineers have seen average salary increases of 7.8% over the past year to $124,000, as shown by the latest remuneration survey from Engineering New Zealand Te Ao Rangahau.
Chief executive Dr Richard Templer says the 2023 results show the profession has grown on the previous year but there are “real challenges” faced by the industry. He says uncertainties surrounding government projects are negatively impacting the profession.
“We are aware of firms having to reduce staff numbers because of the cancellation or delay of projects. We need central and local government to rapidly agree on priorities and recommence work on these important projects,” he says.
In the longer term, New Zealand needs about 2,500 new engineers every year to keep up with growth, but Engineering New Zealand estimates domestic tertiary institutions are currently only graduating about 2,000 engineers annually.
Templer says immigration can help but not solve the problem. “We operate in a globally competitive market. There’s a global shortfall of engineers, and a greater long-term demand for engineers here in Aotearoa than supplementary immigration can provide,” he says.
The usual pathway into engineering requires a foundation in science and maths. But over the last decade, the number of students challenging NCEA in chemistry, physics and maths has declined by up to 25%.
Templer says it’s time for New Zealand to “unlock opportunities in the education system to grow the pool of engineers”, and that Engineering New Zealand and industry organisations have written to the Minister for Education to express their shared concern and desire to partner with government to find solutions. He says Engineering New Zealand’s programme the Wonder Project – which helps inspire students to pursue careers in science, technology, engineering and maths – recently lost its long-standing government funding.
“Engineers are needed to help solve some of society’s most pressing issues like mitigating and adapting to climate change, ensuring we have clean water and a safe and resilient built environment – as well as endless possibilities at the frontier of digital engineering, food production, healthcare, and space exploration,” says Templer.
“Our latest remuneration survey confirms prospects are bright for young people choosing a career in engineering,” he says.
Looking forward to running into the zones at AMW2024
While the clock ticked down to the opening of AMW2024 at the ICC in Darling Harbour in Sydney, the list of exhibitors is impressive, with many large Australian present, as well as a great range of up-and-coming SMEs.
There are seven zones, each with a particular focus within their sector of manufacturing. There’s an ‘Australian Manufacturers Pavilion’, and companies supporting manufacturing are in the ‘Manufacturing Solutions Zone’. There’s ‘Robots’, there’s ‘Air Compression and Welding’, there’s ‘Plastics’, and there’s the ‘Additive Manufacturing Zone’.
The AMW2024 show opens at 10am each day. Registrations are now open for Australian Manufacturing Week (AMW2024), which will occupy more than 6,764 square metres of exhibition space at the MCEC, with over 270 organisations taking stands to showcase the latest manufacturing technologies, processes, and support services.
Sky Window Construction expands national footprint, opens Wellington showroom
Sky Window Construction Limited, an innovator in the New Zealand building and construction industry, has opened a Wellington office and showroom in 18 Cable Street, near Te Papa.
The company supplies superior commercial, thermally broken aluminum and steel joinery to the New Zealand construction, property development and residential sectors.
The showroom was officially opened by Hon Chris Bishop, MP for Hutt South, at a function on 26 March.
A wide range of representatives from the building and construction sectors attended the opening, including property developers and architects. Also attending were representatives from German company RP Technik (world leaders in steel glass systems) and SYP Glass in China.
Sky Window Construction is a New Zealand owned and operated company.
From a Petone base it was established in 2018 through the entrepreneurship and construction sector experience of owner/directors Tony Gray and Zhe Li.
The company’s director, Tony Gray says,“We are expanding our national footprint, including on-the-ground distribution agents and installers in Auckland, and soon in the South Island.
“Our business has grown through a progressive business model, based on innovation, efficiency, value-for-money and eco-responsibility.
“We see this expansion as a vote of confidence in the New Zealand building and construction sectors. Also, a vote of confidence in the New Zealand economy.
“All our products are eco-responsible, and we are committed to helping solve the housing supply challenge in New Zealand.”
SMC’s high-performance JSB angle valve series boosts flow rates
To maintain a competitive edge in today’s fast-paced market, local industries are investing in new-generation solutions designed to improve performance, enhance productivity, and bolster performance.
With this in mind, automation specialist, SMC Corporation Australia New Zealand (ANZ) recently announced the introduction of its JSB series angle seat valve, with Rod Ryan, head of field sales SA & strategic projects for SMC ANZ saying that “angling a valve can offer big benefits.”
“One of the key benefits to customers is the fact that the angle seat structure reduces pressure loss. This is particularly important in a time where every saving counts in boosting company’s bottom line and reducing energy loss,” says Ryan.
Offering a long service life and a large flow rate, the JSB series is a great choice for steam, air and water applications in a wide range of industries such as water management, diary, food and beverage and other process controls.
The JSB series is an air operated valve, featuring an angle seat structure to minimise pressure loss. It delivers up to three million cycles for steam applications, and up to 10 million cycles in air and water applications.
“Thanks to the JSB’s optimised flow channel shape, a larger flow rate is possible, with a valve flow coefficient of approximately 2.5,” says Ryan.
“The addition of a new scraper function to the squeeze seal inside the valve enables more effective shut off of fluid leakage. A guide bushing prevents misalignment of the valve components during operation, and lengthens the life of the squeeze valve.”
The JSB series is an all-in-one valve with all stainless-steel construction, available with port sizes in 3/8″ to 2″. It’s robust and can handle fluids with high temperatures (up to 183°C for steam, and 99°C for air and water, respectively).
With its compact design (measuring just 166 mm in height), a built-in visual indicator and low maintenance requirements, this valve is easy to install and to use.
“The modular design ensures each part of the valve – from the head assembly and body nut, down to the valve element assembly – can be replaced as needed, further simplifying maintenance of the valve,” says Ryan.
The JSB Series is available in seven size variations, to suit different application requirements, with optional fittings available for pilot ports and breathing ports.
“We’re excited to introduce the JSB Series to the local market.”
Welding wellness: Protecting lungs, enhancing productivity and health
There are no ‘safe’ welding fumes, and while local exhaust ventilation (LEV) systems may meet WorkSafe standards, on-gun fume extraction is one of the safest and most effective methods of controlling welding fume says NZ Safety Blackwoods.
“All updates from WorkSafe now use the wording ‘fume capture’, not ‘fume extraction’,” says Roy Ford, NZ Safety Blackwoods’ regional power tool and welding specialist. “With on-gun systems like Translas, fume is removed directly at source, giving you a very high capture rate, which benefits not only the welder but everyone else in the factory.”
The Translas On-gun Fume Extraction System has a fume capture rate of up to 98% with a 100% duty cycle.
“These results are scientifically proven, with a peer-reviewed study published in the Safety Journal in 2023,” says Sean Maher, sales manager at Apex Welding Safety, a key supply partner with NZ Safety Blackwoods, looking after training and installation of Translas equipment. “We wrote a white paper on the study that discusses the results and provides clear and actionable guidance on how best to control welding fume.”
Meeting WorkSafe standards
The risks posed by welding fume are serious, and excessive exposure can cause multiple types of cancer, including in the lungs, larynx and urinary tract. Welding fumes can also cause serious long-term health effects like lung function abnormalities, stomach ulcers, and kidney and nervous system damage.
WorkSafe is actively enforcing the standards, coming down harder on non-compliance.
Standard LEV systems have inherent limitations in their effectiveness; fume arms and hoods must be positioned as close as possible to the source to maximise capture rates, and also be the right design for the process and type of fumes.
Lightweight for greater productivity
“With LEV systems, welders have to constantly move the capture nozzle,” says Ford. “It takes time, and the effectiveness relies on how focused they are at repositioning the capture nozzle throughout the day.”
“Translas guns have a lightweight, ergonomic design that is the same weight as or lighter than a traditional welding gun,” says Maher. “This follows the welder as they move, providing continuous fume capture on a 100% duty cycle.”
For the welder, this translates to increased productivity in a number of ways. There is no moving of extraction devices, and extraction at source creates a vortex around the torch, keeping the tip cooler. This means tips and tip adaptors need to be replaced less frequently, saving time and cost.
Easy maintenance
Built with Dutch engineering, Translas on-gun fume extraction is a high-quality system designed for maximum performance and minimal maintenance. Maher says, “With a built-in variable-frequency drive motor and programmed logic chip, it maintains the capture rate regardless of filter load. It uses a brushless motor, and also has a self-cleaning filter when connected to compressed air, so there is no need for back-end servicing.”
For more information email translas@nzsafetyblackwoods.co.nz or phone 0800 660 660.
The Emperor is using apps
By Craig Carlyle, certified machinery safety expert (TÜV Nord), HasTrak
I have run into a number of companies lately that have dealt with their health and safety responsibilities with app-based solutions. On the face of it, these plug and play solutions appear fantastic; all of your staff are now connected to the system and the opportunity to complete documentation on the fly is enabled.
Sounds like Nirvana.
However, when you scratch below the surface, disturbingly these same companies believe that the ‘app’ is their health and safety system.
The emperor is using an app. We need to talk.
Just like in maintenance management systems, the head over heels rush to view everything on our smart phones can distract us from the real task of managing our systems. It is all too easy for the inexperienced to get over-excited about their phone app while forgetting completely what we are trying to achieve. Under our health and safety statute and supporting regulations, we need a system to detail the hazards and risks in our operation, ensure our hazard controls are continuously managed, and capture our continuous learning to ensure mistakes are not repeated. These are the things that are measured and tested in Court if things go wrong.
When we get to the business end of those systems and processes, yes, connectivity, transparency and on the fly, reporting are fantastic enhancements to a system. But they do not replace the system. Plugging into a blunt app (often supported outside of the country) for your documents and actions is not a substitute for your health and safety system. Having a health and safety system that your app taps into for transactional entries is an enhancement to your system.
So, if you get it right, you will already have a health and safety system. It will describe your health and safety policy, how you manage health and safety including hazards, workers, specific actions, and detailed policies. Your system should be transparent and transportable across the company. In the modern world we can achieve this with Cloud based applications. Like any process, your health and safety system needs
- A defined and agreed process.
- A complete process (no bypasses).
- A published process (how you do things).
- Clear responsibilities.
- Clear and timely performance measures.
- Regular management reporting.
This is where the true management happens. From the system, supporting documents and forms become the transaction statements and the recorded results become the proof of your good management, vital in defending prosecutions.
Now you are ready to consider the distributed end of your process; safety inductions, training records, safety data sheets, safe work instructions, permits, hazard and incident reporting. If your workers are out in the field, yes, an app may be the answer. Not so good if they have no cell phone coverage, (particularly within sandwich panel factories), or if phones are banned in the working environment. Is the best solution a piece of paper, an app, or a tablet? Certainly, a digital solution should be superior to analogue methods. If you can find a solution to fit your situation, you should enjoy a more complete management solution. But don’t fall into the trap of thinking an app by itself is going to keep your workplace compliant and safe.
Craig Carlyle is director at Maintenance Transformations. His expertise lies in the practical application of maintenance and health and safety management systems in the workplace. He is also a life member of the Maintenance Engineering Society of NZ.
Exciting careers for more women in STEM, automation
Swisslog senior solution architect, Sally Renwick
Swisslog senior solution architect, Sally Renwick, is fascinated by “the side of industry many never see” – the high achieving world of automation that is opening up a broad range of satisfying careers for women entering STEM (science, technology, engineering, and mathematics) and automation fields.
The numbers may show that women are outnumbered by men in STEM industries, with the Australian Academy of Science reporting that “only 16% of Australia’s STEM-skilled workforce are women, whereas the broader Australian workforce has close to 50% female participation,” but Renwick says women shouldn’t be daunted when seeing these statistics.
“Despite what the numbers say, I see lots of high achieving women in warehouse automation, and the numbers are increasing every year. It’s an exciting field, so people who overcome their initial hesitation often find highly rewarding careers,” she says.
Renwick believes the exciting side of working in automation may not be obvious from the outside, and encourages more women to look deeper as they explore STEM career options.
“This industry is changing all the time – just look at what happened with e-commerce in response to the pandemic. There’s never a dull day, and you’re learning new things all the time,” she says.
“From the outside, it might look like you are just writing code – which some people enjoy – but when you look at what that code achieves, or the problem solving involved in designing solutions, it becomes a much more fascinating job.”
To nurture and grow your career, Renwick’s advice is to speak up and be clear about the direction you’d like to move into.
“It’s important to ask for help and guidance to achieve your career aspirations. Swisslog has been very supportive in this way, and any company with a healthy culture will want to see its employees grow and develop. If you’re new, it’s a great idea to find a mentor who you can learn from as you develop into your role,” she adds.
The 2024 theme for International Women’s Day is “inspire inclusion” which Renwick says in a work context, is all about making workplaces safer and more welcoming spaces for women to thrive.
Renwick started with intralogistics leader, Swisslog, in 1997 as a software engineer, where her first site visit was to a Jaguar automotive facility where automation was storing and retrieving painted car bodies ready for the production line.
“I was intrigued by this side of the industry that you never see. You can extend this to things like supermarkets too. We all add products to our trolleys, but the journey it took to get there – and the technology that enabled it – is remarkable,” she adds.
As a solution architect with Swisslog, Renwick now sits between sales and realisation, and is responsible for translating customer requirements into technical solutions that the software development team can implement.
As automation evolves, solutions are becoming more complex, with greater numbers of different configurations possible for each technology. This provides greater benefits to the customer, but also creates additional challenges for a solution architect like Renwick.
“One challenge I faced recently was a customer site that had two different Swisslog warehouse automation systems in place, of different ages, and running different software systems. Initially we wanted to migrate the whole site to run as one system, but there were complex factors that made the customer reluctant to take that option,” she explains.
“It was such a large and customised site that I could see the customer’s concerns in migrating to a unified system, and instead worked on a solution that would optimise replenishment, while still having the two systems operating separately. I designed a high-level solution to keep the systems operating separately, but with Swisslog’s latest SynQ software still replenishing the older system, to gain the benefits of the newer software.”
“It was a powerful, cost-effective solution that the customer was happy with, and that was a very satisfying moment in my career.”
And while Renwick is especially proud of achievements like this one, she adds that the satisfaction of writing software code and watching a pallet move in a warehouse was equally satisfying in the beginning of her career.
“Right from the start, knowing that my input made that technology move – I knew I was in the right industry to build my career.”
MIT ENGINEERS 3D PRINT
THE ELECTROMAGNETS AT THE HEART OF MANY ELECTRONICS
Imagine being able to build an entire dialysis machine using nothing more than a 3D printer.
This could not only reduce costs and eliminate manufacturing waste, but since this machine could be produced outside a factory, people with limited resources or those who live in remote areas may be able to access this medical device more easily.
While multiple hurdles must be overcome to develop electronic devices that are entirely 3D printed, a team at MIT has taken an important step in this direction by demonstrating fully 3D-printed, three-dimensional solenoids.
Solenoids, electromagnets formed by a coil of wire wrapped around a magnetic core, are a fundamental building block of many electronics, from dialysis machines and respirators to washing machines and dishwashers.
The researchers modified a multi-material 3D printer so it could print compact, magnetic-cored solenoids in one step. This eliminates defects that might be introduced during post-assembly processes.
This customised printer, which could utilise higher-performing materials than typical commercial printers, enabled the researchers to produce solenoids that could withstand twice as much electric current and generate a magnetic field that was three times larger than other 3D-printed devices.
In addition to making electronics cheaper on Earth, this printing hardware could be particularly useful in space exploration. For example, instead of shipping replacement electronic parts to a base on Mars, which could take years and cost millions of dollars, one could send a signal containing files for the 3D printer, says Luis Fernando Velásquez-García, a principal research scientist in MIT’s Microsystems Technology Laboratories (MTL).
“There is no reason to make capable hardware in only a few centres of manufacturing when the need is global. Instead of trying to ship hardware all over the world, can we empower people in distant places to make it themselves? Additive manufacturing can play a tremendous role in terms of democratizing these technologies,” adds Velásquez-García,
MIT researchers modified a multi-material 3D printer so it could produce three-dimensional solenoids in one step by layering ultrathin coils of three different materials. It prints a US quarter-sized solenoid as a spiral by layering material around the soft magnetic core, with thicker conductive layers separated by thin insulating layers. IMAGE: Courtesy of researchers.
FIRE AND GAS MAPPING…
IMPROVE HAZARD DETECTION AND WORKPLACE SAFETY
Fire and gas mapping (FGM) is used to improve safety and reduce the effects of flammable gas releases, toxic gas releases and fire hazards found at major hazard facilities.
If you manage or work at locations with fire and gas hazards, fire and gas mapping can be used to accurately design an effective fire and gas detection system to mitigate the specific hazards found at the facility.
Equinox Automation is a specialist instrumentation and control engineering consultancy offering a range of engineering services. The company has experienced engineers that have delivered FGM studies across a broad range of New Zealand industries including offshore facilities, oil and gas production, hydrogen production and storage, process industry, geothermal binary power plants, compressor stations, and industrial ammonia refrigeration plants.
“An effective fire and gas system (FGS) is a final barrier to reducing harm when all other barriers have failed,” says Hardie McLaren, founder/senior engineer at Equinox Automation.
McLaren says that New Plymouth-based Equinox Automation is expert in process industry fire and gas systems and detection technologies.
The main purpose of an FGS found in industrial plants is to detect a hazard early and to reduce the effects of a hazard before it escalates. To achieve this, a FGS should have these primary functions built into the system: detecting and warning people of hazards, activating automatic shutdowns and initiating emergency operating procedures.
“FGM is an engineering process that can be used in the design phase of a project, or as a method to evaluate existing systems. This process involves a range of engineering tasks,” says McLaren.
These could include:
• Reviewing of site fire and gas hazard risks.
• Hazard screening – gas dispersion modelling, fire modelling.
• Fire and gas risk assessments.
• Selecting detector coverage targets to reduce facility hazard risks.
• Developing coverage maps with specialist 3D software.
• Layout optimisation to ensure no blind spots and lowest quantity of detectors.
• Designing coverage verification.
• Optimised gas detector positioning with CFD modeling.
• Developing site detector layout drawings.
• Documenting in a FGM study report with key activities, results, and recommendations.
Historically, fire and gas detection layouts were determined using rule of thumb methods, or by simply drawing circles on a layout drawing. Even though these methods may have reduced engineering costs upfront, they could not provide assurance that the hazard risks had been correctly quantified and mitigated within the design. Something common with these design methods, actual real gas releases are not detected due to design errors in detector quantities and placement.
“With a small investment, using the latest fire and gas mapping techniques will provide assurance that a fire and gas system is designed correctly to detect and mitigate specific fire and gas hazard risks found at a facility.”
According to McLaren, another benefit of a correctly designed FGS, if following IEC Standard IEC-61511 Functional safety – Safety instrumented systems for the process industry sector, the FGS can be used as a risk reduction credit within LOPA risk assessments.
“So, while improving process plant safety, an effective FGS will significantly reduce project costs related to functional safety risk reduction achieved with safety instrumented systems (SIS).
Lead process safety engineer of one local energy utility business was thankful the team at Equinox Automation was on hand to assist: “Their expertise and recommendations will make a significant difference at our facility, and we are grateful for their support”.
McLaren adds that Equinox Automation is committed to helping industries improve workplace safety with “safer and more effective fire and gas system designs to help protect people, assets, and the environment from harm caused by fire and gas hazards”.
For more information phone 0800 4 EQUINOX or visit www.equinoxautomation.co.nz.
Transforming industry – exploring the application of advanced manufacturing in New Zealand.
By Dr Troy Coyle, HERA CEO
Recently, HERA visited Australia with Minister for Small Business and Manufacturing Hon Andrew Bayly and heavy engineering industry representatives to better understand how Australia is responding to the Industry 4.0 revolution.
This visit included a tour of both the University of Wollongong’s Facility for Intelligent Fabrication (FIF) and the $81 million Australian Composite Manufacturing Co-operative Research Centre (ACM CRC). Gaining access to these impressive facilities demonstrated how the use of cutting-edge technology is revolutionising manufacturing in Australia and its potential to do the same in Aotearoa. It was also clear that long-term funding (in the case of the CRC program, which is ten-year funding) and industry-led research are key to successful industry transformation through the adoption of these technologies.
We were also proud to see HERA acknowledged as a key partner in several of the ACM CRC’s projects, including the application of AI to quality systems, circular design of composite materials, technical and scientific barriers for robotics and automation in composite manufacturing, and waste management in the composite industry.
Industry 4.0, also referred to as the fourth Industrial Revolution, is a broad term for new technologies and data such as cloud computing, the Internet of Things (IoT), and artificial intelligence. The future of manufacturing will require widespread adoption of Industry 4.0 technologies to transform how goods are made by optimising processes and driving the potential for unprecedented efficiency and productivity gains.
These advances have been a core focus for HERA to understand in order to drive the transformation of New Zealand’s manufacturing sector and its future readiness. We want to see our sector at the cutting edge of these developments, so we have been focused on developing our facilities and supporting research and services to help our manufacturing and construction sectors understand the potential for uptake.
Knowing how to incorporate these new technologies into business models can be difficult and requires a financial commitment that is not often achievable for businesses with no innovation strategies in play. In driving the adoption of Industry 4.0, it is not so much about focusing on the underlying technologies (although this is very important), but more so, helping our industry understand how these technologies can support their businesses. Having industry come along on this trip as part of the delegation was a great way to achieve this. We were delighted to accompany the Minister in this tour. HERA has long advocated for the need for a Minister of manufacturing. We look forward to working with the Minister in this space and seeing how the manufacturing sector can grow and thrive as one of his portfolio
Engineer salaries increase but short-term challenges and skills crisis looming
Engineers have seen average salary increases of 7.8% over the past year to $124,000, as shown by the latest remuneration survey from Engineering New Zealand Te Ao Rangahau.
Chief executive Dr Richard Templer says the 2023 results show the profession has grown on the previous year but there are “real challenges” faced by the industry. He says uncertainties surrounding government projects are negatively impacting the profession.
“We are aware of firms having to reduce staff numbers because of the cancellation or delay of projects. We need central and local government to rapidly agree on priorities and recommence work on these important projects,” he says.
In the longer term, New Zealand needs about 2,500 new engineers every year to keep up with growth, but Engineering New Zealand estimates domestic tertiary institutions are currently only graduating about 2,000 engineers annually.
Templer says immigration can help but not solve the problem. “We operate in a globally competitive market. There’s a global shortfall of engineers, and a greater long-term demand for engineers here in Aotearoa than supplementary immigration can provide,” he says.
The usual pathway into engineering requires a foundation in science and maths. But over the last decade, the number of students challenging NCEA in chemistry, physics and maths has declined by up to 25%.
Templer says it’s time for New Zealand to “unlock opportunities in the education system to grow the pool of engineers”, and that Engineering New Zealand and industry organisations have written to the Minister for Education to express their shared concern and desire to partner with government to find solutions. He says Engineering New Zealand’s programme the Wonder Project – which helps inspire students to pursue careers in science, technology, engineering and maths – recently lost its long-standing government funding.
“Engineers are needed to help solve some of society’s most pressing issues like mitigating and adapting to climate change, ensuring we have clean water and a safe and resilient built environment – as well as endless possibilities at the frontier of digital engineering, food production, healthcare, and space exploration,” says Templer.
“Our latest remuneration survey confirms prospects are bright for young people choosing a career in engineering,” he says.
Looking forward to running into the zones at AMW2024
While the clock ticked down to the opening of AMW2024 at the ICC in Darling Harbour in Sydney, the list of exhibitors is impressive, with many large Australian present, as well as a great range of up-and-coming SMEs.
There are seven zones, each with a particular focus within their sector of manufacturing. There’s an ‘Australian Manufacturers Pavilion’, and companies supporting manufacturing are in the ‘Manufacturing Solutions Zone’. There’s ‘Robots’, there’s ‘Air Compression and Welding’, there’s ‘Plastics’, and there’s the ‘Additive Manufacturing Zone’.
The AMW2024 show opens at 10am each day. Registrations are now open for Australian Manufacturing Week (AMW2024), which will occupy more than 6,764 square metres of exhibition space at the MCEC, with over 270 organisations taking stands to showcase the latest manufacturing technologies, processes, and support services.
Sky Window Construction expands national footprint, opens Wellington showroom
Sky Window Construction Limited, an innovator in the New Zealand building and construction industry, has opened a Wellington office and showroom in 18 Cable Street, near Te Papa.
The company supplies superior commercial, thermally broken aluminum and steel joinery to the New Zealand construction, property development and residential sectors.
The showroom was officially opened by Hon Chris Bishop, MP for Hutt South, at a function on 26 March.
A wide range of representatives from the building and construction sectors attended the opening, including property developers and architects. Also attending were representatives from German company RP Technik (world leaders in steel glass systems) and SYP Glass in China.
Sky Window Construction is a New Zealand owned and operated company.
From a Petone base it was established in 2018 through the entrepreneurship and construction sector experience of owner/directors Tony Gray and Zhe Li.
The company’s director, Tony Gray says,“We are expanding our national footprint, including on-the-ground distribution agents and installers in Auckland, and soon in the South Island.
“Our business has grown through a progressive business model, based on innovation, efficiency, value-for-money and eco-responsibility.
“We see this expansion as a vote of confidence in the New Zealand building and construction sectors. Also, a vote of confidence in the New Zealand economy.
“All our products are eco-responsible, and we are committed to helping solve the housing supply challenge in New Zealand.”
SMC’s high-performance JSB angle valve series boosts flow rates
To maintain a competitive edge in today’s fast-paced market, local industries are investing in new-generation solutions designed to improve performance, enhance productivity, and bolster performance.
With this in mind, automation specialist, SMC Corporation Australia New Zealand (ANZ) recently announced the introduction of its JSB series angle seat valve, with Rod Ryan, head of field sales SA & strategic projects for SMC ANZ saying that “angling a valve can offer big benefits.”
“One of the key benefits to customers is the fact that the angle seat structure reduces pressure loss. This is particularly important in a time where every saving counts in boosting company’s bottom line and reducing energy loss,” says Ryan.
Offering a long service life and a large flow rate, the JSB series is a great choice for steam, air and water applications in a wide range of industries such as water management, diary, food and beverage and other process controls.
The JSB series is an air operated valve, featuring an angle seat structure to minimise pressure loss. It delivers up to three million cycles for steam applications, and up to 10 million cycles in air and water applications.
“Thanks to the JSB’s optimised flow channel shape, a larger flow rate is possible, with a valve flow coefficient of approximately 2.5,” says Ryan.
“The addition of a new scraper function to the squeeze seal inside the valve enables more effective shut off of fluid leakage. A guide bushing prevents misalignment of the valve components during operation, and lengthens the life of the squeeze valve.”
The JSB series is an all-in-one valve with all stainless-steel construction, available with port sizes in 3/8″ to 2″. It’s robust and can handle fluids with high temperatures (up to 183°C for steam, and 99°C for air and water, respectively).
With its compact design (measuring just 166 mm in height), a built-in visual indicator and low maintenance requirements, this valve is easy to install and to use.
“The modular design ensures each part of the valve – from the head assembly and body nut, down to the valve element assembly – can be replaced as needed, further simplifying maintenance of the valve,” says Ryan.
The JSB Series is available in seven size variations, to suit different application requirements, with optional fittings available for pilot ports and breathing ports.
“We’re excited to introduce the JSB Series to the local market.”
Welding wellness: Protecting lungs, enhancing productivity and health
There are no ‘safe’ welding fumes, and while local exhaust ventilation (LEV) systems may meet WorkSafe standards, on-gun fume extraction is one of the safest and most effective methods of controlling welding fume says NZ Safety Blackwoods.
“All updates from WorkSafe now use the wording ‘fume capture’, not ‘fume extraction’,” says Roy Ford, NZ Safety Blackwoods’ regional power tool and welding specialist. “With on-gun systems like Translas, fume is removed directly at source, giving you a very high capture rate, which benefits not only the welder but everyone else in the factory.”
The Translas On-gun Fume Extraction System has a fume capture rate of up to 98% with a 100% duty cycle.
“These results are scientifically proven, with a peer-reviewed study published in the Safety Journal in 2023,” says Sean Maher, sales manager at Apex Welding Safety, a key supply partner with NZ Safety Blackwoods, looking after training and installation of Translas equipment. “We wrote a white paper on the study that discusses the results and provides clear and actionable guidance on how best to control welding fume.”
Meeting WorkSafe standards
The risks posed by welding fume are serious, and excessive exposure can cause multiple types of cancer, including in the lungs, larynx and urinary tract. Welding fumes can also cause serious long-term health effects like lung function abnormalities, stomach ulcers, and kidney and nervous system damage.
WorkSafe is actively enforcing the standards, coming down harder on non-compliance.
Standard LEV systems have inherent limitations in their effectiveness; fume arms and hoods must be positioned as close as possible to the source to maximise capture rates, and also be the right design for the process and type of fumes.
Lightweight for greater productivity
“With LEV systems, welders have to constantly move the capture nozzle,” says Ford. “It takes time, and the effectiveness relies on how focused they are at repositioning the capture nozzle throughout the day.”
“Translas guns have a lightweight, ergonomic design that is the same weight as or lighter than a traditional welding gun,” says Maher. “This follows the welder as they move, providing continuous fume capture on a 100% duty cycle.”
For the welder, this translates to increased productivity in a number of ways. There is no moving of extraction devices, and extraction at source creates a vortex around the torch, keeping the tip cooler. This means tips and tip adaptors need to be replaced less frequently, saving time and cost.
Easy maintenance
Built with Dutch engineering, Translas on-gun fume extraction is a high-quality system designed for maximum performance and minimal maintenance. Maher says, “With a built-in variable-frequency drive motor and programmed logic chip, it maintains the capture rate regardless of filter load. It uses a brushless motor, and also has a self-cleaning filter when connected to compressed air, so there is no need for back-end servicing.”
For more information email translas@nzsafetyblackwoods.co.nz or phone 0800 660 660.
The Emperor is using apps
By Craig Carlyle, certified machinery safety expert (TÜV Nord), HasTrak
I have run into a number of companies lately that have dealt with their health and safety responsibilities with app-based solutions. On the face of it, these plug and play solutions appear fantastic; all of your staff are now connected to the system and the opportunity to complete documentation on the fly is enabled.
Sounds like Nirvana.
However, when you scratch below the surface, disturbingly these same companies believe that the ‘app’ is their health and safety system.
The emperor is using an app. We need to talk.
Just like in maintenance management systems, the head over heels rush to view everything on our smart phones can distract us from the real task of managing our systems. It is all too easy for the inexperienced to get over-excited about their phone app while forgetting completely what we are trying to achieve. Under our health and safety statute and supporting regulations, we need a system to detail the hazards and risks in our operation, ensure our hazard controls are continuously managed, and capture our continuous learning to ensure mistakes are not repeated. These are the things that are measured and tested in Court if things go wrong.
When we get to the business end of those systems and processes, yes, connectivity, transparency and on the fly, reporting are fantastic enhancements to a system. But they do not replace the system. Plugging into a blunt app (often supported outside of the country) for your documents and actions is not a substitute for your health and safety system. Having a health and safety system that your app taps into for transactional entries is an enhancement to your system.
So, if you get it right, you will already have a health and safety system. It will describe your health and safety policy, how you manage health and safety including hazards, workers, specific actions, and detailed policies. Your system should be transparent and transportable across the company. In the modern world we can achieve this with Cloud based applications. Like any process, your health and safety system needs
This is where the true management happens. From the system, supporting documents and forms become the transaction statements and the recorded results become the proof of your good management, vital in defending prosecutions.
Now you are ready to consider the distributed end of your process; safety inductions, training records, safety data sheets, safe work instructions, permits, hazard and incident reporting. If your workers are out in the field, yes, an app may be the answer. Not so good if they have no cell phone coverage, (particularly within sandwich panel factories), or if phones are banned in the working environment. Is the best solution a piece of paper, an app, or a tablet? Certainly, a digital solution should be superior to analogue methods. If you can find a solution to fit your situation, you should enjoy a more complete management solution. But don’t fall into the trap of thinking an app by itself is going to keep your workplace compliant and safe.
Craig Carlyle is director at Maintenance Transformations. His expertise lies in the practical application of maintenance and health and safety management systems in the workplace. He is also a life member of the Maintenance Engineering Society of NZ.
Exciting careers for more women in STEM, automation
Swisslog senior solution architect, Sally Renwick
Swisslog senior solution architect, Sally Renwick, is fascinated by “the side of industry many never see” – the high achieving world of automation that is opening up a broad range of satisfying careers for women entering STEM (science, technology, engineering, and mathematics) and automation fields.
The numbers may show that women are outnumbered by men in STEM industries, with the Australian Academy of Science reporting that “only 16% of Australia’s STEM-skilled workforce are women, whereas the broader Australian workforce has close to 50% female participation,” but Renwick says women shouldn’t be daunted when seeing these statistics.
“Despite what the numbers say, I see lots of high achieving women in warehouse automation, and the numbers are increasing every year. It’s an exciting field, so people who overcome their initial hesitation often find highly rewarding careers,” she says.
Renwick believes the exciting side of working in automation may not be obvious from the outside, and encourages more women to look deeper as they explore STEM career options.
“This industry is changing all the time – just look at what happened with e-commerce in response to the pandemic. There’s never a dull day, and you’re learning new things all the time,” she says.
“From the outside, it might look like you are just writing code – which some people enjoy – but when you look at what that code achieves, or the problem solving involved in designing solutions, it becomes a much more fascinating job.”
To nurture and grow your career, Renwick’s advice is to speak up and be clear about the direction you’d like to move into.
“It’s important to ask for help and guidance to achieve your career aspirations. Swisslog has been very supportive in this way, and any company with a healthy culture will want to see its employees grow and develop. If you’re new, it’s a great idea to find a mentor who you can learn from as you develop into your role,” she adds.
The 2024 theme for International Women’s Day is “inspire inclusion” which Renwick says in a work context, is all about making workplaces safer and more welcoming spaces for women to thrive.
Renwick started with intralogistics leader, Swisslog, in 1997 as a software engineer, where her first site visit was to a Jaguar automotive facility where automation was storing and retrieving painted car bodies ready for the production line.
“I was intrigued by this side of the industry that you never see. You can extend this to things like supermarkets too. We all add products to our trolleys, but the journey it took to get there – and the technology that enabled it – is remarkable,” she adds.
As a solution architect with Swisslog, Renwick now sits between sales and realisation, and is responsible for translating customer requirements into technical solutions that the software development team can implement.
As automation evolves, solutions are becoming more complex, with greater numbers of different configurations possible for each technology. This provides greater benefits to the customer, but also creates additional challenges for a solution architect like Renwick.
“One challenge I faced recently was a customer site that had two different Swisslog warehouse automation systems in place, of different ages, and running different software systems. Initially we wanted to migrate the whole site to run as one system, but there were complex factors that made the customer reluctant to take that option,” she explains.
“It was such a large and customised site that I could see the customer’s concerns in migrating to a unified system, and instead worked on a solution that would optimise replenishment, while still having the two systems operating separately. I designed a high-level solution to keep the systems operating separately, but with Swisslog’s latest SynQ software still replenishing the older system, to gain the benefits of the newer software.”
“It was a powerful, cost-effective solution that the customer was happy with, and that was a very satisfying moment in my career.”
And while Renwick is especially proud of achievements like this one, she adds that the satisfaction of writing software code and watching a pallet move in a warehouse was equally satisfying in the beginning of her career.
“Right from the start, knowing that my input made that technology move – I knew I was in the right industry to build my career.”
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