deployment of robotics with virtual simulation …
TRANSCRIPT
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EM - Interview
Manish Bhatnagar,Managing Director, SKF India (p. 18) Artificial Intelligence P. 32
Auto-components Manufacturing P. 20
Rapid Prototyping P. 24
Test & Measurement P. 28
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DEPLOYMENT OF ROBOTICS WITH VIRTUAL SIMULATION
Making manufacturing flexible & efficient
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EFFICIENT MANUFACTURING
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EM - Interview
Petr Novotny,Managing Director Scania Commercial Vehicles India (p. 30)
FOCUS Cutting Tools P. 38
SPECIAL FEATURE Industrial Maintenance P. 54
3EM | S e p 2021
ED ITOR IAL
COVID-19 affected the economies of the entire world, including that of India. But our economy has recovered more strongly than it was halted by the pandemic, said Prime Minister Narendra Modi. As per the data released by the National Statistical Office (NSO) recently, India’s economic growth surged to 20.1% in the April-June quarter of this fiscal, and the industrial output grew 11.5% in July. Many of the sectors including manufacturing, mining, electricity, capital goods posted robust growth on easing of restrictions after the second wave of COVID-19. The manufacturing sector, in particular, grew an annual 10.5% in July 2021 as compared with a drop of 12.7% in July 2020. Overall, several indicators have pointed to a recovery in the sector and the economic growth is projected to grow in double digits for the current financial year.
Although the pandemic has exposed the fragility of the world’s supply chains, there are many companies which have begun to reconfigure their sourcing and manufacturing footprints for greater reliability and resilience, setting up more locations so that they don’t have to depend on just a few geographies. So, developing globally competitive manufacturing hubs represents one of the biggest opportunities for India to drive economic growth and job creation in the coming years.
In fact, global investors seem to be upbeat about investing in India, with India faring better than Singapore and Japan to emerge as a top choice in Asia for global investors, according to a recent Deloitte global survey. Also, as per a statement from the Government of India, there are over a dozen entities, existing as well as new players, which are looking to invest about $4 billion in the automobile sector in India, which will provide a further boost to domestic production and job creation.
In short, India stands out as a potential manufacturing powerhouse that has yet to realise its promise.
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Shekhar Jitkar Publisher & Chief [email protected]
EDITORIAL ADVISORY BOARD
Raghavendra RaoCEO, Kaizen Hansei LLP
Dr N RavichandranFormer Executive Director,Lucas-TVSChief Mentor,UCAL Fuel Systems
Dr Ravi M DamodaranChief Technology Officer, Greaves Cotton
Dr P N RaoProfessor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Ramesh T KMD & CEO, Micromatic Machine Tools
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Vineet SethManaging Director,Mastercam India
Sonali KulkarniPresident & CEO,Fanuc India
Dr Wilfried AulburManaging Partner,Roland Berger Pvt Ltd
Satish GodboleVice President, Motion Control Div,Siemens Ltd
Overseas Partner:
China, Taiwan, Hong Kong & South-East Asia
“Developing globally competitive manufacturing hubs represents one of the biggest opportunities for India to drive economic growth and job creation in the coming years”
India - a potential manufacturing powerhouse!
EM | S e p 2021
4 EM | S ep 2021
RAPID PROTOTYPINGRapid prototyping: Past, present and future of manufacturing
CONTENTSMARKET 08 NEWS
11 “Lubrication innovation for ultimate performance”Interview with Rupinder Paintal, Director – Market Development, ExxonMobil Lubricants Pvt. Ltd
START-UP
12 “The e-bike market is at a growing stage”Interview with Sumedh Battewar, Co-founder and CBO, EMotorad
WORLD AFFAIRS
13 AGVs & AMRs advancing material handling in the factoryThe opinion feature analyses how AGVs & AMRs are at the core of the warehousing market and how robotisation of material handling is a financial essential
EVENT REPORT
34 3D Printing - Its impact on manufacturing & supply chain operations A post-event report on the recently held Virtual Additive Manufacturing Congress which discussed the development of 3D Printing applications, the impact of Additive Manufacturing on the supply chain and more
MANAGEMENT INTERVIEW
18 “We need to have a one-nation-one-policy kind of an approach across the country”Manish Bhatnagar, Managing Director, SKF India
FOCUS AUTO-COMPONENTS MANUFACTURING
20 Digital twin approach in smart manufacturing of traction motorsThe digital twin approach plays an important role in smart manufacturing in the auto-components industry. The article explains the smart manufacturing approach using digital twins of the key machines and processes.
14COVER STORYDeployment of robotics with virtual simulation: Making manufacturing flexible & efficient
24
5EM | S e p 2021
TEST & MEASUREMENTBetter accuracy to redefine quality norms and reduce costs
28
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VIEWPOINTCollaborative
Robots P. 32
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A&D - Interview
Hans Bangert
Managing Director,
Bosch Rexroth India (p.32)
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Marc Jarrault
Managing Director,
Lapp India (p.34)
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Aerospace & Defence P. 28
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Dr Nagahanumaiah,Director,CMTI (p. 28)
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EM - InterviewSanjay Chavre,Sr Development Officer, Dept
of Heavy Industry – Ministry
of Heavy Industries & Public
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FOCUS Automotive Plastics P. 40
VIEWPOINT Industry Associations – Bringing the sector closer P. 32
TECHNOLOGY COVER STORY
14 Deployment of robotics with virtual simulation: Making manufacturing flexible & efficientThe Cover Story discovers how the right 3D virtual environment transforms the accuracy of robotics deployment to meet manufacturing goals
RAPID PROTOTYPING
24 Rapid prototyping: Past, present and future of manufacturingThe article talks about the advantages of rapid prototyping and factors that ought to be thought of
TEST & MEASUREMENT
28 Better accuracy to redefine quality norms and reduce costsThe case study explains how Godrej Tooling Division (Godrej) relies on Renishaw solutions to save time, money, reduce scrap & achieve a high level of accuracy
ROBOTICS
30 Passenger to freighter retrofitting aircraftThe case study talks about how the spindle for the robot cell that comes from Zimmer Group came to the rescue of Helios Applied Systems and also supplied a storage station for the wooden shank tapers
SPECIAL FEATURE ARTIF ICIAL INTELLIGENCE
32 Industry 4.0 and AI – Driving flexible factories of tomorrowThe article talks about the integration of AI into manufacturing & how engineers with domain knowledge will be the most needed for future factories
New Products37 Machinery and processes monitoring
module; Decentralised frequency inverter; Double-edged cutting inserts; Face mill for roughing to semi-finishing operations
Columns03 Editorial 04 Contents 06 Guest Editorial38 Highlights – Next Issue38 Company Index
ARTIFICIAL INTELLIGENCEIndustry 4.0 and AI – Driving flexible factories of tomorrow
32
6 EM | S ep 2021
GUEST ED I TOR IA L
It is quite evident that electric vehicles are the future of the automobile industry. For a long time, we have relied on fossil fuel-based vehicles, but now, the time has come for us to commit ourselves to an electric future. According to a report by Mordor Intelligence, the Indian electric vehicle market was valued at US $5 billion in 2020 and is expected to reach US $47 billion by 2026, registering an impressive CAGR of more than 44%. That being said, there are a few obstacles that are hindering the growth of the electric vehicle industry in the country which need to be addressed. These are as follows:
The challenges Lack of charging infrastructure: While several EV manufacturers have released models with batteries that offer great economy and range, the lack of charging infrastructure is dissuading many potential buyers. However, many state governments have noticed this problem and have jumped into action. Range anxiety: Since this issue is closely linked to the lack of charging infrastructure, improvements in that regard would help alleviate this concern. Swappable batteries can also help solve this issue to a great extent.
CO
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Forging the futureRegardless of the challenges, the
electric vehicle industry is growing rapidly and in time, the few challenges that it’s facing will be addressed – especially since the government itself is focusing on incentivising EV adoption and manufacturing.
Recently, the government has made some modifications to the Faster Adoption and Manufacturing of Electric Vehicles in India scheme (FAME II). According to these amendments, the demand incentive for electric two-wheelers (e2W) has been increased by 50% from ₹10,000/kWh to ₹15,000/kWh. The maximum cap on incentive for electric two-wheelers has also been increased 20% of vehicle cost to 40% of vehicle cost. An increase of this magnitude in demand incentive (in the form of higher subsidy) will help bridge the price gap between EVs and ICEs and promote EV adoption in the country.
To boost production in the country, Niti Ayog, during September 2020,
announced incentives worth $4.6 billion by 2030 for companies manufacturing advanced batteries, starting with cash and infrastructure incentives of $122 million in the next financial year, which would then be ratcheted up annually. Moreover, the Delhi government has approved more than 100 models of vehicles, including 45 makes of e-rickshaws and 12 of four-wheelers, for subsidy under the new electric vehicles policy.
All the electric vehicles priced up to ₹15 lakhs will be eligible for the subsidy, besides exemption of road tax and registration fee. Although the vehicles priced more than ₹15 lakhs will not get the subsidy, they will still be eligible for road tax and registration fee exemptions.
Besides these moves, the government has also adopted a policymaking approach that seeks to favour FDI. India already has an abundance of manpower and resources, and by collaborating with foreign technology partners, we can certainly become a global manufacturing hub for electric vehicles. So, not only would the growth of the electric vehicle industry make the country cleaner and greener but it would also contribute massively to economic growth – which is extremely important in the current times. ☐
“INDIA ALREADY HAS AN ABUNDANCE OF MANPOWER
AND RESOURCES”
Gunjan Malhotra,DIRECTOR, KOMAKI ELECTRIC VEHICLE DIVISION
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8
Schneider Electric launches Partnerships of the FutureSchneider Electric recently showcased pioneering energy management innovations and partner programmes during its ‘Partnerships of the Future fueling sustainability and efficiency’ – LinkedIn Live event. To address the global urgency of climate change and the 21st century’s most significant challenges of the accelerating energy transition and growing demand for energy, the company is launching Partnerships of the Future. Exchanging his views, Rohan Kelkar, Executive VP, Power Products, cited, “Digital technologies are a catalyst for business growth. Yet, the inherent complexities that digital transformation projects bring with them may cause decision paralysis and implementation delays. This is why our goal is to face up to the digital challenge and enable the market through 'Partnerships of the Future' by equipping our partners with strategies, solutions and services for increased sustainability & efficiency.” Moving further, Nikhil Pathak, VP - Central Offer Marketing & BD, Schneider Electric India, added, “Our open platforms empower collaboration and foster increased support to build state-of-the-art infrastructures and scalable mechanisms. Our digital solutions will help in pivoting businesses not only at CapEx but also through OpEx.”
Godrej & Boyce partners with Indian Railways to develop Universal Coach Assembly stationGodrej & Boyce recently announced that its business, Godrej Tooling, has partnered with the Indian Railways to design and develop the Universal Coach Assembly station as an indigenous solution for coach assembly fabrication in the brand new Marathwada Railcoach Factory in Latur, Maharashtra. Speaking about this, Pankaj Abhyankar, Sr VP & Business Head, Godrej Tooling, commented, “Our team carried out extensive studies of the current manufacturing processes which included in-depth interactions with the factory personnel at the Integrated Coach Factory (ICF) in Chennai. This helped us design the flexible Universal Coach Assembly station with an automated welding arrangement which can accommodate multiple coach variants. The team, committed to the vision of a stronger railway network, successfully installed and commissioned both the assembly stations through the pandemic. We look forward to further associating with the Indian Railways and strengthening our partnership. In the next three years, we plan to grow the industrial machines business by ₹100 crores.”
MARK E T NEWS
Hexagon teams up with CMTI to support India's push for smart manufacturingHexagon has entered into a partnership with India's Central Manufacturing Technology Institute (CMTI) to establish a Smart Manufacturing Development and Demonstration Cell (SMDDC), an Industry 4.0 Centre of Excellence and Experience Centre, at the CMTI premises in Bengaluru. Expressing his views about the initiative, Dr Nagahanumaiah, Director, CMTI, cited, “We are delighted to associate ourselves with Hexagon as our vision to build a smart manufacturing facility and demo centre under the SAMARTH Udyog initiative is coming to fruition. We would like to invite Indian design and manufacturing organisations to come and experience smart manufacturing and how it could help them for their specific requirements.” Sharing his views on this collaboration, Sridhar Dharmarajan, Executive VP & MD, Hexagon’s Manufacturing Intelligence, India, articulated, “We believe this project will go a long way in promoting indigenous research and developing cost-effective, state-of-the-art technology through Industry 4.0 and building the required expertise for smart manufacturing in India. We are proud to collaborate and are fully committed in this initiative with CMTI to drive the adoption of Industry 4.0 technologies.”
EM | S ep 2021
Ultraviolette announces its manufacturing facility in BengaluruUltraviolette recently announced that it is setting up its manufacturing and assembling facility near Electronics City, Bengaluru. The production of its high-performance electric motorcycle, the F77, will begin in Q1, 2022 and the first batch of motorcycles will be rolled out in the market in March 2022. Speaking about the facility, Narayan Subramaniam, Founder & CEO, Ultraviolette, stated, “We chose this location given its strategic proximity to our R&D facility in Bengaluru as well as a strong supply chain ecosystem in and around the region. Most importantly, the F77 has been designed and built indigenously, and over 90% of the vehicle, including the battery packs, will be manufactured using locally sourced components.” Further, Niraj Rajmohan, Founder & CTO, Ultraviolette, acknowledged, “Our new production unit is a state-of-the-art facility that will be equipped with smart technologies and Industry 4.0 solutions. All processes within the unit will be driven by data in order to ensure seamless integration across the entire manufacturing lifecycle, thereby increasing efficiencies and production output.”
9EM | S e p 2021
National Aerospace Laboratories adopts Dassault Systèmes’ Solutions to design civil aircraft in IndiaDassault Systèmes recently announced that National Aerospace Laboratories (NAL), a constituent of Council of Scientific and Industrial Research (CSIR), has adopted the ‘Passenger Experience’ industry solution experience based on the 3DEXPERIENCE platform to design civil aircraft in India, specifically the Saras Mk-2 program. Talking about the use of 3DEXPERIENCE platform, Jitendra J Jadhav, Director, NAL, said, “The 3DEXPERIENCE platform-based ‘Passenger Experience’ solution has been deployed in designing the cabin and cockpit of the Saras Mk-2 program. Virtual twin-based insights offered by this solution helped us to configure the cabin for various use cases and scenarios.” Further, expressing his views, Deepak NG, MD – India, Dassault Systèmes, stated, “Dassault Systèmes is enabling companies in the aerospace and defence sector by providing new ways to conceptualise, design, manufacture, test, certify and sustain new air & space vehicles. We have long been an integral part of the aerospace industry globally and we intend to replicate the success in India through the association with NAL and in the local development of civil aircraft.”
NEWS MARKET
Sandvik to acquire CNC Software IncSandvik recently signed an agreement to acquire CNC Software Inc, which results in gaining the Mastercam software suite with an installed base of around 270,000 licenses/users. Giving his insights on the acquisation, Stefan Widing, President & CEO, Sandvik, cited, “An acquisition of CNC Software and the Mastercam portfolio, in combination with our existing offerings and extensive manufacturing capabilities, will make Sandvik a leader in the overall CAM market measured in installed base.” Adding to it, Mathias Johansson, President – Design & Planning Automation Division, Sandvik Manufacturing Solutions, said, “Mastercam will be the cornerstone in Sandvik’s CAM portfolio, further improving machining productivity by combining our machining know-how with their CAM expertise to improve quality and reduce waste for our customers.” Sharing her views, Meghan West, CEO, CNC Software, Inc, revealed, “Together we will harness our joint resources to accelerate the development of Mastercam, while continuing to maintain our unique standards of local support through our experienced global reseller channel.”
Manufacturing sector would contribute 25% of the GDP by the end of 2022: Heavy Industries MinisterThe Associated Chambers of Commerce and Industry of India (ASSOCHAM) recently organised a virtual conference on ‘Global Value Chains – Backward and Forward integration’. The session on ‘Smart Manufacturing & Industry 4.0 – Delivering the next generation of manufacturing’ was addressed by Dr Mahendra Nath Pandey, Minister, Ministry of Heavy Industries and Public Enterprises, Government of India. Speaking at the session, Pandey stated, “The government’s focus on manufacturing through programmes, such as ‘Make in India’ and policies, such as the ‘National Policy for Advanced Manufacturing’, Industry 4.0 could play a key role in boosting the manufacturing sector’s share in the country’s GDP to 25% by 2022 from the current 17%.”
Deciphering the future of the manufacturing industry in the country, Vineet Agarwal, President, ASSOCHAM, pointed out, “The focus on manufacturing will help India in leveraging its demographic dividend, as the vast youth population of the country can be engaged in the sector. This mandates a strong skilling focus to enhance employability and reduce the burden on the agricultural industry. However, India would need to strike a balance between emerging technologies and massive labour force.”
Moving further, Vinod Pandey, Chairman, ASSOCHAM Manufacturing & Capital Goods Council and Director – Government Affair and External Affairs, BMW India, added, “The acceleration of the fourth industrial revolution - Industry 4.0 or Connected Factory – however holds the power to steer the industry out of the current crisis. Breakthrough technologies, like Artificial Intelligence (AI), Machine-to-Machine (M2M) learning, Internet of Things (IoT), sensors and advanced analytics can equip manufacturers with the tools and foresight they need to thrive in the post-COVID-19 world.”
Similarly, Kulwin Seehra, Chairman, Punjab State Development Council & Executive Director, GNA Axles, informed, “The government initiatives to popularise digital technology solutions are helping the industry recognise the importance of digital capabilities, such as AI and IoT. Both automation and manual labour can work together. In critical process where there is a huge risk to human life a lot of processes can be automated. This would also help in achieving more productivity.”
10 EM | S ep 2021
EMO Hannover repositioning – Focus on the future of industrial production“Hello, new EMO Hannover!” is the greeting that was shared at the EMO Hannover Relaunch Conference in the hybrid event hub “H’UP” on
the Hannover Messe trade fair grounds. As organisers of EMO Hannover, the German Machine Tool Builders’ Association (VDW) had invited international media representatives and exhibitors to a digital presentation of the new exhibition concept recently. “The sector is in a constant process of transformation and is facing huge challenges. As the leading global trade fair, EMO Hannover must reflect these, make them transparent, and propose solutions, if it is to continue to be of relevance for the future,” explained Dr Wilfried Schäfer, Executive Director, VDW.
‘Innovate manufacturing’ as incentive & claim in one‘Innovate manufacturing’ is the new claim of EMO Hannover 2023. “It addresses the challenges that will face the industry in the months and
years ahead,” Carl Martin Welcker, General Commissioner of EMO Hannover 2023, explains. It is an invitation to everyone involved in EMO, exhibitors as well as visitors, to be constantly reinventing themselves, improving and expanding their offers, streamlining their processes and tapping new markets so as to position themselves as best as possible amidst international competition. At the same time, the claim describes EMO Hannover as an innovation platform for production technologies that has evolved into an internationally relevant business platform – for more than just the exhibition period. To which Welcker added that the fair demonstrates the full breadth and depth of the technologies for renewing and optimising industrial production. “But ‘Innovate manufacturing’ addresses more than just technologies. In fact, EMO Hannover will also be taking on board topics in the future that are of relevance for production technology and for its customer industries throughout the world,” said Welcker in his keynote on ‘Challenges for production 2023’. The future insights of EMO Hannover 2023 – “The future of connectivity”, “The future of sustainability in production” and “The future of business with focus on Work 4.0” – are already the subject of intensive discussions in the business world and in society at large. Welcker feels strongly, “As we see it, without laying any claim to exhaustiveness, these are the key topics that the industry and society as a whole will have to tackle in the years to come in order to make themselves fit for the future and the urgent tasks in hand such as energy revolution, climate change, sustainability in production, new competitors, the transformation of key customer industries, digitisation, changes in the employment world, new data-driven business models and many more.” And none of these are standalone. Far more, they are interlinked, mutually enriching and have to be dealt with & solved together in order to be fully effective. Over and above these, of course, the classics – quality, efficiency, flexibility and reliability – will also be addressed, since they still continue to set the tone for developments in production technology. “We have initiated a dialog by means of the EMO Hannover Relaunch Conference,” said Welcker. “The diverse challenges will not have been resolved by the time of the next EMO Hannover in 2023, but exhibitors and their customers will have hit the road together on this journey, and in Hannover, they will present what they have achieved by then,” the General Commissioner announced.
EMO Hannover as a key real & digital meeting point for the industry “Dialog and encounter are two of the most crucial elements for the new EMO Hannover. Already apparent in the mode of address, this is
evident at many points in the new EMO presence and is also carried forward in a clearly structured communication concept,” said Schäfer, picking up the thread once again. The communication concept rests on the four pillars – EMO Communication, EMO Connect, EMO Digital and EMO Conference. These include new formats such as speakers’ corner, master classes or EMO Academy, as well as familiar offers such as matchmaking or guided highlight tours – including digitally.
Besides that, however, the aspiration of the new EMO Hannover is to become established as the key meeting point for the industry, obviously during the exhibition itself, but also between events, with an accompanying digital program, 365 days a year. “The point is to develop and shape these formats with our partners by the time of the exhibition,” Schäfer announced. There will be a large number of events around the globe in the run-up to EMO Hannover 2023.
Then, in summing up, he added, “Since 1975, EMO has been the world’s leading trade fair for metalworking. It is now more than that. It encompasses the entire value chain, primarily integrating the IT that is so essential for continuing to drive forward intelligent factory networking. These digital twins will always be a feature of EMO Hannover in the future.”
MARK E T NEWS
11EM | S e p 2021
MARKET I NTERV IEW
The IHS Markit India Manufacturing Purchasing Managers’ Index surged to 55.3 in July 2021, bringing
promise for the sector. This pandemic has witnessed a change in manufacturers’ perspective – many
are now moving towards sustainable practices for greener business operations. Besides, the lubricant
industry is also preparing to fulfil the rising need for customized and specialty products – this is a great
opportunity for us at Mobil™ Lubricants to drive transformation.
What do you think will be the new challenges and trends dominating the manufacturing industry?
“ Lubrication innovation for ultimate performance”
Rupinder Paintal, Director – Market Development, ExxonMobil Lubricants Pvt. Ltd., discusses the driving role of innovation in
formulating the most suitable lubrication solutions – in this interview with Juili Eklahare. Excerpts…
How is Mobil innovating to keep up to the new normal?
With the pandemic, the digital switch has become the new normal. Duly, to deliver despite restrictions,
we have drawn focus to providing superior service through remote assistance. The Mobil™ Solcare
Service application has been a breakthrough in providing digital services with immediacy and accuracy.
It conveys immediate data to the user with in-app feedback and performance ratings. The Mobil ServSM
Lubrication Analysis (MSLA) and Mobil ServSM Advanced Analysis (MSAA) programs also deliver a full-
spectrum analysis and trouble shootings on the usage and maintenance of lubricants. The digital era is
here – and we at Mobil are determined to lead innovation as we have over 150 years.
How does Mobil assist customers in selecting precise lubricants for their unique challenges?
As lubricant usage is linked closely to factors like environmental conditions, speed, load, etc., – adopting
correct practices is imperative. For instance, using the appropriate grade and type of lubricant is essential
to preventing shortened bearing life. Over the years, our lubrication solutions and application expertise have
assisted manufacturers in enhancing operations, improving safety, and streamlining maintenance. To achieve
utmost efficiency, we provide them with a variety of products, along with timely servicing and industry insight.
What are some products by Mobil for India’s manufacturing sector?
The manufacturing sector is key to India’s growth. Here, operations are conducted in diverse terrains,
temperatures, and operational climates. Our products attempt to solve specific challenges. For instance,
the Mobil DTE 10 Excel™ Series lubricants assist in reducing power consumption and increasing
machine output. Additionally, the Mobil Vactra™ Oil Numbered Series are specifically designed to meet
requirements of accuracy, aqueous coolant separability and equipment protection of precision machine
tools. These are some examples of a diverse portfolio we have built to deliver to Indian circumstances.
Mobil comes with a legacy of rich customer engagements. Can you share an anecdote of any such successful association with an Indian manufacturer?
We engage very closely with customers. We had collaborated to solve a challenge at Microtech CNC,
Tamil Nadu. Their end product showed black stains on the surface even after thorough washing. To
correct this, they approached us for advice. After conducting investigations, our engineers at Mobil
recommended the use of Mobilcut™ 250 – a high performance, versatile, semi-synthetic water-
soluble metalworking fluid. With use, Microtech CNC reported net savings of Rs 8,40,000 per annum,
oil cost reduction of 15% and tool cost reduction of 7% – along with reduction in top-up by 9.5% and
increase in slump life by 3 months. The final product was also without stains.
(ExxonMobil Corporation has numerous affiliates, many with names that include ExxonMobil, Exxon, Esso and Mobil. For convenience & simplicity, those terms and references to “corporation”, “company”, “ExxonMobil”, “EM”, & other similar terms are used for convenience and may refer to one or more specific affiliates or affiliate groups.)
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I NTERV IE W S TA RT-U P
Doodle is the SUV of electric bikes to reduce human effort. Made for urban lifestyle, the
responsive e-brakes ensure safety when riding in high traffic areas, increasing productive time
and keeping one fit. As for EMX, it is India’s first dual suspension e-cycle with long battery life. It
has 36V 250W BLDC rear hub motor which is powered with a 36V 10.4Ah Samsung lithium-ion
battery (removable) and weighs 21 kg.
Can you tell us in brief about your product, Doodle and also your flagship model EMX?
“The e-bike market is at a growing stage”...says Sumedh Battewar, Co-founder and CBO, EMotorad (an EV start-up that aims to bring across premium quality made
in India electric cycles) in this interview with Juili Eklahare. He throws light on the growth of the e-bike market, why the company
does not consider turning standard bikes into e-bikes and why it is making UAE its stepping stone in the outside world. Excerpts…
Several popular e-bike companies are lowering prices. So, do you see the e-bike market coming back to normal?
Many e-bike companies are trying to enter into the entry-level segment. So, everyone is trying
to enter the market with an entry-level product at the price point, which is starting at ₹25,000 to
₹28,000, considering people will not extend the budget. However, our experience is otherwise.
Our entry-level model is starting at ₹39,000 while our flagship model, EMX, is placed at
₹55,000. So, the e-bike market itself is growing; there is no normal level set as of now. The
market is in a growing stage and we expect it will continue to grow at 22% CAGR.
How innovative have you been in your manufacturing processes of e-bikes? To be more specific, did you ever consider turning standard bikes into e-bikes?
We have never considered and nor will consider turning a standard bike into an e-bike, because it is not
a scalable business at all. The quality of the bike will directly depend upon the person who is assembling
it and it is impossible to monitor. The quality process that we follow in our plant cannot be implemented
at a roadside shop, so we are never going to go into converting standard bikes into electric bikes.
Do you think that with concessions and no mandatory registrations for e-bikes, it could lead to uncontrolled congestion and low credibility of e-bikes?
I do not feel so. People not having an entry barrier is going to be a key concern of the segment
because if one doesn’t have to register then there are no quality parameters being monitored. I
don’t feel the registration of e-bikes will ever get mandated. So, if this is the challenge, then we
have to live with it.
How do you plan to expand in the upcoming years? Why are you making UAE your stepping stone in the outside world?
This financial year, we are reaching 350 touchpoints across the country, spanning over 110 plus
cities. That is what our domestic expansion target is. As for UAE, there is one major reason why
we entered it. Dubai is the gateway to the world. And our motto to come to the UAE is to cater to a
broader segment of the audience. We wish to work very closely with our overseas partners as well
as the government. As a matter of fact, post-launch, we have received enquiries from more than
12 countries, where they are asking us to launch our brand there.
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WORLD AFFA IRS OP IN ION
EM | S e p 2021
AGVs & AMRs advancing material handling in the factory
Industrial automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) outshine at safely and reliably, transporting products and materials in manufacturing and distribution operations. They are a profitable solution that upsurge competence and develop working conditions. In fact, they offer a more flexible and steadfast substitute to conventional material transport methods like, manual transport, static conveyors and fork trucks.
With AGVs, the supply chain sector is scoring fresh and ground-breaking ways of material handling. AGVs have been transforming the material handling domain. The influence of these smart mobile robots has come upon the world and welcomes novel progresses that are fundamentally shifting the industry every year. New research says that mobile robotics in material handling and logistics will become a $75 billion market by 2027 and will be more than double by 2038.
With the pandemic, aspects like contactless operations and safety are important and being examined keenly. Therefore, material handling equipment and automation solutions are popular. It stands true that with the disposition of automation, old-style low skill jobs of handling material might drop out of the picture. However, we must also remember that this generates new jobs, which require applying the little grey cells to make decisions. So, companies have to back their workforce in skilling them to a higher level and train them for jobs that bring in more significance than before.
Also, with environmental mindfulness and the thrust from the government, the demand for sustainable equipment is on the rise. Hence, electric or lithium-ion range of forklifts have also been coming into the picture. Battery operated forklifts of different kinds have made a big place for themselves in the industry in the country.
COVID-19 has made it amply clear to managers at manufacturing plants, third party logistics companies (3PLs) and distribution centres (DCs) that robotisation of material handling is a financial essential. According to Grand View Research, the global market for automated forklift trucks will have an annual growth of 15.6% through 2025.
However, robots’ abilities to pilot around an intricate and complex space have been one of the foremost difficulties. The demand for higher well-being, effortlessness, flexibility and accurateness has only risen during the pandemic.
AGVs & AMRs are at the core of the warehouse market and account for most revenue and shipments. According to ABI Research, global commercial robot revenue in warehouses will have a compounded annual growth rate of over 23% from 2021 to 2030 and exceed $51 billion by 2030. Businesses should be able to react to new changes and have the right space for AGVs & AMRs, particularly in material handling, which is the pillar of the supply chain.
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Juili Eklahare, Features Writer
14 EM | S ep 2021
COVER STO RY T EC HNOLOG Y
It’s becoming increasingly urgent to quickly integrate robotics in production lines to become more efficient with fewer workers and increase the output per worker to meet future demand. The Cover Story discovers how the right 3D virtual environment transforms the accuracy of robotics deployment to meet manufacturing goals.
Michael Mayr, Director of Business Development, Dassault Systèmes
Tony Karew, Senior Specialist, DELMIA Robotics Portfolio, Dassault Systèmes
DEPLOYMENT OF ROBOTICS WITH VIRTUAL SIMULATION Making manufacturing flexible & efficient
14 EM | S ep 2021
COVER STO RY T ECHNOLOG Y
15EM | S e p 2021
TECHNOLOGY COVER STORY
While the robotics market continues to expand—slated to enjoy 9.9% CAGR until the end of the decade—there is a growing need to ensure the accurate deployment of robotics in increasingly complex manufacturing environments. First, products are becoming increasingly personalised in what’s known as ‘Production of One,’ that is, manufacturers need to be flexible enough to produce for the unique needs of a single consumer. Second, global manufacturers have to contend with the prospects of a fast-greying population. There isn’t enough available labour to replace retiring talent; therefore, robotics will have to be more quickly integrated to provide a production multiplier effect to meet projected demand levels. Third, manufacturers have to deliver innovative products in diverse global markets beset with the prospect of volatility and disruption. In these scenarios, coordination of distributed production lines is paramount, and manufacturers have to become more agile in modifying their production lines in response to these challenges.
Flexible manufacturing system
“While robotic systems are extremely flexible, it’s up to the manufacturer or the robotics system integrator to quickly develop or modify a robotics system to solve a problem,” explained Tony Karew. In many cases, these stakeholders don’t consider how to fully utilise such a flexible manufacturing system. They don’t have an avenue to explore all the possibilities and simulate the implementation of highly flexible systems. Because their current approach is too focused, they don’t always have a complete view of the shop floor to realise the other issues they could alleviate with that system, Karew added.
Therein lies the value of virtual simulation for manufacturing. It is the only avenue for innovative manufacturers to advance the deployment of flexible robot systems to:
• Increase the production output of personalised products across multiple lines
• Discover new ways to create innovative products more quickly
• Reduce production costs, especially within research and development (R&D)
• Decrease R&D risks and improve risk appetite to test new ideas and product innovation
The new robotics deployment paradigm
To increase the integration of robotics systems in manufacturing, the right robotics design and deployment solution needs to cater to various end-users at different maturity points. This includes teams consisting of people with and without the skills and knowledge to use simulation to deploy manufacturing robotics.
In the new robotics deployment paradigm, multidisciplinary stakeholders need to be united on the same collaboration platform to leverage powerful virtual simulation capabilities that can account for variables such as:
• Planning for space on the factory floor and power use• Ensuring that operations do not endanger human workers• Defining how robots can fit into existing production line
practices• Ensuring that robots are compatible with the tools needed
for the jobs• Understanding industrial equipment coordinationWhen the value of manufacturing robotics is improved,
manufacturers can expect to avoid costly mistakes, increase production agility and maximise resource efficiency.
The collaborative approach to more efficient & safer robotics integration
The right virtual simulation capabilities gives multidisciplinary stakeholders the tools they’ll need to make
There is a growing need to ensure the accurate
deployment of robotics in increasingly complex
manufacturing environments
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COVER STO RY T ECHNOLOG Y
robotics deployment successful.With safety, for instance, this virtual simulation environment
helps both designers and engineers to accurately visualise:• Where and how the robots are working• How they can best program and configure workcell safeties• Ensure compliance with various regulatory safety
requirementsThe 3D representation of the robotics workcell in situ
greatly enhances how multidisciplinary stakeholders can modify and enhance robots in the context of its production line over its lifetime. These modifications and enhancements include changing the peripherals and programmable logic controllers (PLCs) in response to new production requirements. With a wider view of the production line, these stakeholders can more accurately implement a maintenance task, realise a new type of product or program the robot to accommodate a new style of an existing product.
This collaboration ability also extends to global operations. “It doesn’t just allow for the implementation and the integration of multiple robot processes that might be happening in a workcell, but also helps integrate with the engineering office, and the design effort there, wherever that office is situated. When manufacturers have a product that’s maturing and changing, they need to be able to better accommodate those engineering changes and seamlessly integrate them into their distributed manufacturing systems so that products can go to market more quickly,” Karew said.
The new robotics deployment paradigm disregards the physical constraints of the engineering office and the production line. Instead, it empowers manufacturing engineers, product design engineers, and tooling design engineers to work seamlessly while being aware of the different changes that are being implemented. What emerges from this new paradigm is the confidence to deploy advanced robotics systems for production lines.
Simulate the deployment of advanced robotics
With new thinking and powerful tools, manufacturers can pave the way for more innovative production lines. They can confidently integrate complex and flexible robotics systems with their production lines with ease because of a new virtual commissioning and cobotics experience.
Virtual commissioning
Virtual commissioning gives manufacturers the ability to test their robotics design solution from the concept phase or parallel to production line planning.
“With hundreds of planned sensors in a production line, it is difficult for a line builder to guarantee that they can finalise the line and start production on time based on necessary modifications and the end-users’ wishes, on top of the original project scope,” explained Michael Mayr. “Those crucial three or four weeks that are set aside for commissioning at the end of production line planning is when things usually go awry as hundreds of misconfigured sensors result in more and more problems to fix and further delays,” he added.
Instead, with the right virtual commissioning capabilities, line and cell builders can determine from the outset how to best design all the production line components, assemble them and subsequently program all the automation to run these lines.
Beyond being able to model the physical behaviours of robots on the production line, the right virtual simulation solutions enable manufacturers to attach a PLC to the workcell—be it a software- or hardware-based controller—to enable communication inside the virtual workcell.
Integrating the teams
Manufacturers can integrate their robotics engineering
Manufacturers can confidently integrate complex and
flexible robotics systems with their production lines
with ease because of a new virtual commissioning
and cobotics experience
17EM | S e p 2021
TECHNOLOGY COVER STORY
teams more closely with the PLC programming and electrical engineering teams, all on the same virtual collaboration platform. As a result, teams can program their automation virtually and look at the designs in a virtual workcell and attach their program to it. They can address all of the devices in that workcell and devise their program around what will be built on the floor before any resources are committed to construction.
This is particularly crucial when production lines have to be quickly altered to allow for different production configurations. Also, with the right simulation tools for virtual commissioning, production engineers can easily assess which kind of robotics elements can be used to quickly scale up output. They can determine the best way to split one production line with ten workers into two production lines with five workers each that are enhanced with collaborative robots.
Human-robot collaboration
Collaborative robotics, or cobots, are robots that do not have to be penned in safety cages to operate but can operate freely and safely alongside human workers, maximising the productivity of both.
It is estimated that, by 2025, cobots will constitute 34% of all robot sales. However, popularising the use of cobots will require the same insight into planning and operations that currently dwells traditional industrial robotics. Fortunately for cell builders and end-users, they can have the right virtual simulation solutions to create these specific cobotic cells or cobotic lines. These tools deliver the capability to virtually realise all of the tasks that the human and cobot are doing, encompassing different parameters around the operation of that workcell. But, beyond the ability to model the behaviour of these cobots, the simulation solutions enable stakeholders to consider the placement and application of peripherals like sensors, scanners, cameras and detectors.
This is a crucial ingredient in the cobotics integration
experience & the ability to simulate the performance of peripherals ensures manufacturers can realise results in the real world.
But using the sensors in the simulation, designers and engineers can simulate a human’s operation in that workcell alongside the cobot. This includes determining:
• How long a person can comfortably reach, grab and manipulate objects in the workcell
• The cobot’s reachability, cycle time and how and when it should react to reduce risk to the human in the workcell
Simulation enables manufacturers to accurately determine the risk that is introduced when a human is within proximity of the robot. The right simulation capabilities help manufacturers to identify the limitations of the cobot physically and from a time standpoint; they can identify time constraints in the practices assigned to the cobots. As a result, a manufacturer can fully utilise their cobotics investment because cobots can be deployed as flexibly as possible to make the production line as smooth as possible.
Virtual simulation & collaborative environment
The changing landscape of the manufacturing workforce is one that, in a decade or two, society is going to see increasing demand but a drop in the talent supply. As such, it’s becoming increasingly urgent to quickly integrate robotics in production lines to become more efficient with fewer workers and increase the output per worker to meet future demand. Furthermore, as manufacturing worker salaries become more costly and products become smarter and more complex, these create increasingly volatile market conditions.
The Dassault Systèmes robotics portfolio on the 3DEXPERIENCE® platform gives manufacturers the ultimate virtual simulation and collaborative environment to explore and identify all the possibilities and nuances that a manufacturing robotics system can assume. ☐
Popularising the use of cobots will require the
same insight into planning and operations that
currently dwells traditional industrial robotics
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MANAGE ME N T I N TERV I EW
EM | S ep 2021
“We need to have a one- nation-one-policy kind of an approach across the country”
…says Manish Bhatnagar, Managing Director, SKF India, in this interview with Juili Eklahare. SKF India provides industry leading automotive and industrial engineered
solutions. Bhatnagar discusses how the next generation of leaders today are more flexible, throws light on what the company is doing to further the government’s
various initiatives and the work it is doing in the EV segment. Excerpts…
no other factors in play?There is no doubt that the pandemic has severely impacted the automobile sector. However, the sector has been experiencing prolonged negative growth for quite some time now. The current decline of the automotive industry can be attributed to various factors – rising fuel prices, slowing income growth and confusion around BSVI emission norms, causing a general slowdown in consumer confidence. Also, in the last few years, the size of organised pre-owned market has expanded significantly, impacting new vehicle demand. Currently, semiconductor shortages are disrupting vehicle sales and this may reverberate all through 2022.
SKF India launched an e-shop concept in the country to boost India’s ‘Digital India’ initiative. What other steps has the company taken to further the government’s other initiatives, for instance, like the Aatmanirbhar Baharat Abhiyan?We have been constantly focused on aligning with key government initiatives, such as Skill India initiative, Aatmanirbhar Bharat Abhiyan and Vocal for Local campaigns to support India’s growth aspirations. To align with the Skill India and Digital India initiatives, we have initiated the Kushal 4.0 programme for our shop floor workers to provide training through IIoT labs. When it comes to Aatmanirbhar Bharat, we have always been invested in India, for India. A majority of our products are for domestic consumption with less than 10% being exported to other markets.
Automotive has been the major target sector for your business. Which are the other sectors in focus? What about the EV segment?In the industrial segment, we have a wide product portfolio of bearings, seals and lubrication systems, coupled with rotating equipment solutions & remanufacturing.
You have taken an active role in mentoring the next-gen leaders. What is it that today’s leaders can learn from them and them from us in the manufacturing industry?The basic principles of mentoring remain unchanged. However, with the shift to a work-anywhere world comes the need for a new kind of employee experience and engagement. The next generation of leaders today are more flexible, more visible and
do not shy away from connecting with employees frequently. And that’s something most of us in
the manufacturing industry can learn. With technology changing, the future
of work continues to evolve. Organisations need to keep pace. The next-gen leaders can learn to have a long-term vision & planning, a systematic approach to talent development and create the right balance of transparency,
empathy & task orientation. With a solid plan, leaders can secure long-term
business success and growth.
Commercial Vehicles are still seeing a downturn in the industry. There is also poor demand for vehicles in current times and challenges that have shaken growth forecast. Would you say that the COVID-19 pandemic is the one and only reason for this downfall? Are there
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I N TERV I EW M ANAGEMENT
EM | S e p 2021
Particularly in railways, we offer solutions for a wide range of wheel set designs for all kinds of railway rolling stock. This includes high-speed trains, diesel & electric locomotives, diesel & electrical multiple units, passenger coaches, freight cars and mass transit vehicles like tram cars.
For EVs, we are investing in new technological developments and adapting or redesigning conventional bearings. Overall, we have a portfolio of innovative solutions that enable a robust and efficient e-powertrain drive. In addition, we are also developing application-specific solutions to mitigate the risk of current leakage at the system level and to protect the entire EV transmission.
SKF has evolved from being a bearing manufacturing company to a knowledge-driven integrated solutions provider. Can you give us more details on this transition?Over more recent years, we have evolved from a product-based bearing and services supplier to a data-driven system solutions provider, with a focus on addressing the specific needs of customers rather than offering one-size-fits-all type solutions. To enable this, we have two strategically different value propositions. On one hand, we provide products that meet the customer’s specific performance requirements, delivered at the requested time and at a competitive cost. On the other hand, we provide additional solutions to help customers improve their Rotating Equipment Performance (REP). Here, the customers see the need to reduce operating costs and to run their machines trouble-free, without unexpected downtime and with their equipment reaching their expected operating life. With REP, the customer needs to pay a monthly fee rather than the cost of the product and we get paid based on the performance we deliver. We essentially are moving from selling products to
selling performance and uptime.
According to Cushman & Wakefield’s recent Global Manufacturing Risk Index 2021, India has emerged as the second most attractive manufacturing hub in the world. What kind of opportunities do you think this opens up for a company like SKF India? Do you think some futuristic decisions need to be taken on the government bringing in policies that can increase India’s purchasing power?For SKF, there is a lot of potential for export. We are also looking at expanding our manufacturing footprint to more locations in India. When it comes to government policies, we need to have a one-nation-one-policy kind of an approach across the country.
Currently, it differs from state to state, and at times, this poses a challenge in the ease of doing business. The other area that the government needs to look into is the infrastructure, especially in the logistic sector. We need to reduce our dependency on roadways and explore railways and waterways. The DFC, I hope, will solve this problem to some extent but there is still a
substantial scope of improvement here. Some of these measures will result in companies increasing their spend quickly.
What do you think the remaining year of 2021 has in store?With the gradual decline in COVID cases pan-India and all the sectors picking up the pre-COVID pace, the remaining year will be beneficial for the manufacturing sector in the country and its impact will be clearly reflected in the GDP numbers. Looking ahead, we continue to execute faster on all our strategic priorities, driving investments to grow the business, gain share and optimise margins. The automotive segment has shown a sharp recovery and the industrial segment has picked up steam and we have had many strategic wins with our key accounts. ☐
WE ARE MOVING FROM SELLING PRODUCTS TO SELLING PERFORMANCE
‘‘
Manish Bhatnagar has nearly three decades of experience in strategic leadership and business operations, and his prior experience includes Unilever, GE and Danaher. Having lived and worked in Asia, Europe and the US, he brings a strong global perspective along with local customer-centricity to drive execution & results. He holds an electronics engineering degree from BITS Pilani and an MBA from IIM Calcutta.
20 EM | S ep 2021
AUTO-CO MPO N E N T S MANUFA C TUR ING FOCUS
Machine-1
Process-1
Machine-n
Process-n
EOL
‘machine data pass bin’
Real time data Machine ‘n’
Digital Twin of TM
Pass/Fail
Data
Data
Data
Data
‘machine data pass bin’
Real time data Machine ‘n’
Digital Twin of TM
Pass/Fail
‘machine data pass bin’
Real time data Machine ‘n’
Digital Twin of TM
Pass/Fail
Digital twin approach in smart manufacturing of traction motors
The digital twin is defined as the living virtual model of a physical system. The live representation of reality via ‘Digital Twin’ allows us to gather real-time data and introduce new manufacturing practices, ensuring robust product development. A reliable, efficient and cost-effective traction motor is essential for the success of e-mobility. Robust manufacturing facilities play an important role in realising the design with minimum performance variation, in-house rejection and warranty. This
article aims to gather critical data from different stages of manufacturing machines, while measuring critical dimensions of the components and comparing them with the real-time models (digital twins) and predicts the performance before ‘EOL (End of Line)’ testing. At EOL, a comparison of test results is performed with the digital twin output. The digital twin is also capable of learning and improving the process based on the rejection it records at EOL or warranty testing.
The digital twin approach plays an important role in smart manufacturing in the auto-components industry. It helps predict the future instead of only analysing the past. In this article, the smart manufacturing approach is explained using digital twins of the key machines and processes. The application of the digital twin is explained in terms of a traction motor manufacturing line.
Lohit Dhamija, Project lead, Varroc Engineering
Dr Prakash Airani Kalathil, Head – R&D, Electrical, Electronics & Lighting Business Unit, Varroc Engineering
21EM | S e p 2021
FOCUS AUTO-COM PONENTS M ANUFACTUR ING
Digital twin technology
The ‘Digital Twin’ technology was conceived by the aircraft industry to predict the structural behaviour of an aircraft in 2011. NASA further defined this technology to mirror the space vehicles’ behaviour to predict and update fleet history and sensor behaviour. Now, the ‘Digital Twin’ technology has evolved into a much broader concept to simulate the behaviour of manufacturing machines, people, assets, and processes. This is possible with the advanced development of number-crunching processors, data acquisition, and machine learning. The Digital twin technology is at the forefront of Industry 4.0 facilitated by data analytics and IoT (Internet of Things) connectivity.
The digital twin is defined as a living model of the physical asset, which continually adapts to operational changes based on collected online data and information and can forecast the future of a corresponding physical counterpart. In this article, a traction motor manufacturing line is used as a research model to define the digital twin technology, its application, and benefits.
The digital twin technology is often confused with a digital model or a digital shadow where no ‘automatic data exchange’ or ‘one-way data exchange’ is established between the physical object and the virtual model. Digital Twin reflects the two-way dynamic mapping between a physical object and its virtual model in cyberspace. The two-way impact, i.e., impact of data on virtual model and impact of decision-making on the physical object is an essential feature of a digital twin. A Digital Twin can provide an abstract physical representation to make real-time decisions. Figure 1 shows a Digital Twin reference model. The development of Digital Twin needs three components (1) An information/mathematical model that abstracts the specifications of a physical object (2) A communication mechanism to transfer data between a Digital Twin and its physical counterpart, and (3) A data processing module that can extract information from many sources to construct the real-time representation of the physical object. These three components must work together to construct a Digital Twin.
It is becoming more evident that Digital Twin runs in parallel with Artificial Intelligence (AI) and IoT technology resulting in
shared challenges. Some of the challenges are IT infrastructure, data, privacy and security, and an increased expectation. The rapid growth of AI needs high performance and an expensive IT infrastructure to process real-time data. High-quality data is needed to produce meaningful results. This means ‘data cleansing’ is important and creates challenges at times. The last challenge for data analytics is the expectation that it can be used to solve all our problems. Careful consideration is vital to identify the correct application, ensuring standard models would not produce the same results. Similar, to other new technologies, they have the potential to work hand-in-hand by strengthening manufacturing. Potential users focus only on the benefits and expect an instant save on time and money. The field is still in an intermediary stage, and the challenges need to be kept in mind while conducting data analytics.
Based on application, the Digital Twin can be segregated into three different categories, namely Unit level, System level, and SoS (System of System) level. The Unit level is the single digital twin model which replicates the behaviour of the unit under consideration. The system-level digital twin can be obtained by integrating multiple unit-level digital twins, and by cooperating with each other. Multiple system-level digital twins constitute the SoS level digital twin.
Traction motor manufacturing & Digital Twin
This session’s focus is to apply the digital twin technology to the traction motor (TM) manufacturing process to ensure a robust product by repeatedly meeting performance requirements, reducing in-house rejection and warranty. A TM manufacturing line has a stator assembly, a rotor assembly, a motor assembly, and the EOL testing system. At the time of design, one should be aware of the control factors that finally determine the ‘Critical to Quality (CTQ)’ factors of the TM. An example would be the magnetic field strength, which has a direct correlation to the maximum torque produced. At the design stage, it is also assumed that the motor virtual model (digital twin) is available, and a good correlation is proven during prototype testing and validation. At this stage, characterisation of the TM and the equivalent circuit
1 | P a g e
Digital Twin (information mode)
Data Processing
Communication
Physical Asset (Machine) Figure 1: A simple reference
representation of the digital twin
22 EM | S ep 2021
AUTO-CO MPO N E N T S MANUFA C TUR ING FOCUS
parameters will enhance the quality of the digital twin for the TM. This enhanced model can provide the acceptable limits of equivalent circuit parameters which will later be utilized for detection at the process phase. This virtual representation can consist of pure mathematical modelling of the TM or a hybrid approach where there can be a combination of mathematical and data-driven methods used. In both cases, one should be able to achieve a good level of accuracy. A mathematical model would be derived using the physics of the system and non-linearities should be considered for achieving more accuracy. The data-driven approach would start with understanding and labelling the collected data, and then using that to build the models.
At the manufacturing line, we need to identify ‘critical to quality’ factors of each machine and the key factors that affect them. In a stator assembly line, the winding machine is an example. The winding strength provides ‘critical to quality’ for the TM performance. The factors affecting these could be estimated from the current and voltage characteristics of the machine actuators. A particular pattern of current and voltage waveform will ensure proper winding strength. So, the data acquisition in this machine can be the current and voltage waveforms. Further characterisation of this machine can help us in correlating equivalent circuit parameters and thereby developing a digital twin of the winding machine. The data captured during the winding process by the machine is assessed in real-time and any anomaly can be detected before the next station. This is an example of a unit-level digital twin for TM manufacturing. Another important consideration during this stage can understand the acceptable limits of the equivalent circuit parameters for the given TM. This can serve as a starting point for baseline models for doing rule-based rejections or
anomaly detection algorithms. These threshold and anomaly detection can provide suitable information for performing a predictive maintenance of the machine.
Similarly, we should be able to identify key machines or processes and related parameters which will impact the performance of the TM. Some examples of such processes can be enamel removal, resistance welding, auto gauging, rotor balancing and correction, cover tightening, etc. All the data is captured in real-time and compared at each stage to ensure there are no errors due to machine wear and tear, or any human intervention.
A data capturing mechanism at the part-inspection stage is also needed to ensure we have the right parts before assembly. An example would be to assess the magnetic field strength of magnets and the material used. Assume that we have the cleaned-up data available from the parts inspection stage and from the key machines and processes as identified before. Let us represent this data as x1, x2 …. xn and y1, y2,… yn, where x represents the data from the winding machine and y represents the data from the parts inspection. Similarly, we can have data from other machines/process from 1,2, … n. This set of data represents all the key machines and processes of the TM line.
Once we achieve this relation for all the critical machines, we will have two sets of data called ‘Machine data pass’ and ‘fail bins’. The number of ‘n’ product samples data can be collected during a sample build and at pre-production stages. If, enough data is not available a set of production samples can also be used to gather the data. The minimum ‘n’ samples of TM can be determined scientifically. Once we have enough sample data, we should be able to arrive at a relation with TM digital twin and the ‘machine data pass bin’. The ‘machine data fail bin’ can be utilised to improve our thresholds and anomaly detection algorithms. There
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‘machine data pass bin’
Real time data from Machine ‘n’
Digital Twin of TM
Pass/Fail
Figure 3: A pictorial representation of the real time algorithm
1 | P a g e
Machine Data Pass Bin
ML/Deep Learning Algo
TM Input (EOL) (Voltage, current)
Min (Error)
Figure 2: Mapping machine data to digital twin of TM
23EM | S e p 2021
FOCUS AUTO-COM PONENTS M ANUFACTUR ING
should be a map between the input to TM and this data set. The result of the classification of Figure 2 will map ‘machine
data pass bin’ to digital twin TM input as in the EOL machine. This input data will be based on the EOL tests and can be logged to create this mapping. Let us call the outcome of this step as ‘EOL input map’. This ‘EOL input map’ can also help us in highlighting the important critical to quality parameters from the list of CTQs selected for building this model.
At this stage, we are ready to use the ‘EOL input map’ and digital twin of the TM to check the machine and the processes at each stage to ensure robust manufacturing. This baseline ‘EOL input map’ can be utilized along with the real EOL data and other continual learning techniques to improve the model further. In the long term as one gains experience, ‘EOL input map’ becomes more accurate, and the dependency on EOL can be reduced.
At each machine stage the data gathered is fed to the ‘EOL input map’ and the digital twin of the TM is executed in real time. If there is any discrepancy at this stage, the process of assembly stops. So, at each stage, say at machine-1, the actual data x1,x2… xn is fed to the ‘EOL input map’ digital twin of the TM, other data from other machines, say 1…n is taken from ‘machine data pass bin’ as it is assuming they are correct.
Summary
The smart manufacturing approach using digital twins will ensure a robust process for product manufacturing and will also consider the wear and tear of the machines recorded at each stage. Weightage of the machines or process parameters can also be considered from the warranty data analysis, ensuring the learning from warranty data is fed back to the digital twin models.
The key steps in the approach are as follows:1. Develop a digital twin of the product under manufacturing
based on its key CTQs.2. Identity key machines and processes contributing to the
product CTQs.3. Identify data to be captured at each stage as identified in
step 2.4. Classify pass and fail machine/process data for ‘n’
samples based on EOL testing results.5. Map the data of step 4 to provide input to the digital twin
of the product.6. At each machine/process execute the digital twin of the
product and pass/fail criteria.7. Maintain the digital twin of the machines/process to
capture learning.A careful analysis and study are required to capture the
required data and filter them to make it useful. This can be a planned stage-wise considering one machine/process at a time and step by step cover all critical stages. ☐
FOCUS A UTO-C OMPONENTS MA NUFACTUR I NG
24 EM | S ep 2021
RAP ID PROTOT Y P IN G T ECH N OL OG Y
Rapid prototyping: Past, present and future of manufacturingRapid prototyping is often a very low cost choice for constructing prototypes, particularly when the cost of the time to manufacture a prototype by means of more traditional methods or waiting for first tooled pieces is brought in. In this article, we talk about the advantages of rapid prototyping, look at advances and audit distinctive prototyping stages & factors that ought to be thought of.
Rapid prototyping is a manufacturing process that promotes innovation by allowing for the rapid production of models, prototypes and other products. Rapid prototyping starts with an idea or concept, which is then translated into design software to create prototypes. The technology was first developed in the 1980s by American inventor, Chuck Hull. He invented stereolithography – a 3D Printing process where liquid plastic is dried by ultraviolet light to create objects one layer at a time.
Rapid prototyping is an affordable way for companies to test out new ideas without having to spend too much money on designs or prototypes. It is also more efficient than other
methods because it reduces the amount of wasted material created during production. This helps companies save on costs and waste management as well as have higher profit margins. Rapid prototyping is extraordinarily expanding the assembling business with its simple change of collecting an actual article from an advanced model to test for structure, fit and capacity. In its easiest terms, it is the most common way of making models to assess a designing item plan.
In a world that is continually looking faster for an ideal opportunity to advertise, innovators need to speed up their time span and builds for next cycle. Rapid prototyping offers organisations the chance to stay cut-throat by
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26 EM | S ep 2021
RAP ID PROTOT Y P IN G T ECH N OL OG Y
presenting new items rapider.
Prototyping: Before the product introduction stage
Models are fundamental, particularly with regards to the new item improvement measure. They assist with wiping out hazard and rejuvenate an item thought. There are many terms thrown around the business when we consider prototyping. The expressions, ‘prototyping’, ‘rapid prototyping’ and ‘3D Printing’ are ordinarily utilised one next to the other. They are utilised reciprocally, however, indeed have various implications.
The contrast between 3D Printing and rapid prototyping
Rapid prototyping is the method of creating a model from a CAD document. 3D Printing/added substance fabricating is the cycle and rapid prototyping is the final product. Rapid prototyping is one of numerous applications under the 3D Printing umbrella. Rapid prototyping is an application utilised in added material assembling to make a model rapider than whatever future thought about the ordinary interaction. Designing Product Design states, "3D imprinting all alone or in blend with different cycles could be utilised to make rapid prototyping."
We should take a gander at the contrast between conventional prototyping and rapid prototyping. Both are progressed handling strategies for models. In any case they utilise something else entirely.
Choosing a rapid prototyping process
To assemble the right model to coordinate with one’s particular prerequisites, one needs to choose which variables are the most basic dependent on his/her circumstance.
Techniques/technology available for different applications
Stereolithography (SLA) – Innovation that changes over
fluid materials, layer by layer, into strong spects by restoring them, utilising a light source measure.
Laser sintering – Added substance fabricating (AM) innovation that uses lasers to sinter powdered plastic material (normally nylon/polyamide) into a strong construction dependent on a 3D model.
Direct Metal Laser Sintering (DMLS) – This is an immediate metal laser liquefying innovation that structures exact and complex calculations impractical with other metal assembling techniques.
Fused deposition modelling – The most generally utilised strategy that utilises a thermoplastic fibre that is warmed to its softening point and constrained out, layer by layer, to make a 3D item.
Multi jet fusion – 3D Printing measure that produces useful nylon models and end-use creation parts as rapid as one day.
Infusion moulding – A strategy to acquire formed items by infusing plastic materials liquid by heat into a shape, and afterward cooling and hardening them. Broadly utilised interaction to make things like plastic knickknacks, water bottles, cell cases, toys and that's just the beginning.
How rapid prototyping fits into the engineering design process
The designing plan measure is the means one goes through to tackle an issue and give an answer. As such, it begins with an issue and finishes with an answer. The means can change contingent upon one’s undertaking, however generally incorporates –
1. Define/clarify 2. Plan 3. Design 4. Build a model 5. Test 6. Iterate 7. Redesign
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TECHNOLOGY RAP I D PROTOTYP ING
An interaction can be applied to any issue. Rapid prototyping squeezes into stage four (build a model). Ideation implies distinguishing expected dangers and setting an assembly in real life. The interaction depends on cycles that produce models that will be tried and refined.
The objective is to concede to the look and feel of a plan preceding building stage. The last process will be the assembling of the item with quality control measures set up.
Benefits of rapid prototyping
Build plan disappointment in the advancement stage can cause a significant misfortune for an organisation. Rapid prototyping is a savvy approach to create and test a thought. The up sides of rapid prototyping can deliver a model to test the item for its functionality and proficiency.
Here are seven benefits for rapid prototyping: 1. Perception of the plan idea will offer one chances to roll out
speedy improvements or alterations. 2. Rapid prototyping can save time and cost which brings about,
generally speaking, decrease of one’s chance to showcase. 3. Plans can be more redone. Changes in plan, materials, size
and so forth.4. Higher precision level in planning can assist with
distinguishing the imperfections and mistakes before the assembling system starts.
5. Diminished waste. 6. Permits usefulness testing. 7. Capacity to assess the human variables and commitment.
Making instructive, educated choices
Rapid prototyping can diminish the time among emphases and permit specialists to find innovative methods of taking care of any plan designing issues. It can be utilised at any phase of the item advancement cycle, yet is best from the get-go in the process so that dangers can be relieved early and plans can develop all the more proficiently. Prototyping helps make instructive, educated choices by social affair information from the presentation and response to the various models.
In spite of the advances in rapid prototyping innovation as of late, numerous specialised difficulties and commercialisation-related difficulties related with the interpretation of rapid prototyping methods to clinical medication and dentistry remain. The fruitful business interpretation of rapid prototyping-delivered orthodontic apparatuses proposes that there is enormous interest among patients and medical services suppliers for patient-explicit gadgets made through rapid prototyping procedures. Working on the mechanical, synthetic and natural properties of rapid prototyping-created items, just as lessening the expense of rapid prototyping instrumentation and feedstock materials, are difficulties that the rapid prototyping local area is attempting to survive.
Furthermore, rapid prototyping in aerospace, space, oil & gas, automotive and the white goods segment offers a huge incentive as making a prototype before the main part is built, saving millions if not billions, offering the benefit of getting the final part made for functional use at the lowest possible time. ☐Courtesy: Objectify Technologies
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Rapid prototyping is a savvy approach to create
and test a thought
28 EM | S ep 2021
TEST & ME ASURE ME N T APPL I CAT I ON S
Accuracy and on-time delivery of projects are key requirements for the tooling industry. This case study explains how Godrej Tooling Division (Godrej) relies on Renishaw solutions to save time, money, reduce scrap and achieve a high level of accuracy.
Godrej is a household name in the Indian market, with international presence in the Netherlands, Saudi Arabia, the UAE, Oman, China, Vietnam, Malaysia and Singapore. Founded in 1935 as a captive tool room, the Godrej Tooling Division commenced commercial operations in 1993 and manufactures press tools, die casts and special-purpose machines, jigs and fixtures. With revenues exceeding ₹ 1.2 billion, the company caters to the tooling needs of Toyota, TATA, Honda, GM, Maruti Suzuki and Siemens amongst others.
Godrej, India’s largest tooling solution provider, has unsurpassed capabilities in the manufacture of complex dies, with 15-20% of its products being exported around the world. As part of its Total Productive Maintenance (TPM) initiative, it
follows Productivity, Quality, Cost, Delivery, Safety and Morale (PQCDSM) and Kaizen guidelines. The main objectives of its TPM initiative are to reduce downtime to zero and ensure on-time deliveries. Therefore, maintaining the accuracy of its equipment, including CNC and EDM machines with high precision calibration equipment is essential.
Evaluation of accuracy
In the early days, Godrej’s evaluation of accuracy was difficult to obtain. National Aerospace Standard NAS979 tests (standardised cutting tests for CNC milling machines) were performed by a highly skilled expert as part of machine
Better accuracy to redefine quality norms and reduce costs
29EM | S e p 2021
APPL ICAT IONS TEST & M EASUREMENT
commissioning. These tests were problematic and time-consuming to carry out. In 1996, Godrej purchased Renishaw’s ML10 laser system after hearing about the quality of the product and was impressed with its accuracy and reliability. Furthermore, Godrej was surprised how simple it was to use and avoided expensive errors common in the NAS test.
Although the ML10 only measured nine parameters, as compared to 13 in NAS tests, the improvement in results quality was more important than the parameters left undiagnosed. The data reading was instant and easy to analyse. Godrej soon realised that the Renishaw laser system would save time, money and reduce scrap. Its accuracy prompted Godrej customers to specifically request ML10 certification. S M Nayak, Senior General Manager, Godrej, explained, “The product is rugged and stable. We only call Renishaw for upgrades. There has never been an instance of product failure.”
Godrej has since upgraded to Renishaw’s XL-80 laser system designed with simplicity and ease of use in mind, reducing the need for a highly skilled expert. Nayak asserted, “Renishaw’s service is second to none and they have an immediate response time. We requested training and were delighted that in a week the training was complete.” The XL-80 laser measurement system offers high performance calibration for motion systems, including CMMs and machine tools.
Identifying machine errors with high accuracy
As part of its expansion, Godrej Machine Tools purchased multiple CNC machines in its tooling division. This posed new challenges as the machines needed to be tested for additional parameters, like circular interpolation and drive tuning. Once again, Godrej turned to Renishaw and found a solution in the QC20-W telescoping ballbar system which identifies machine
errors easily with a high degree of accuracy. It directly determines servo mismatch, geometric accuracy, squareness, positional errors and reversal spikes in all three planes (xy-yz-zx). Since the adoption of QC20-W ballbar testing, Godrej’s downtime and rejection rates have reduced.
Delivering results
In the tooling industry, quality parameters are critical and customers expect a product lifespan of 10 years. Through its adherence to the highest quality and accuracy standards, Godrej has been able to deliver products with a lifespan of 125,000 cycles, far ahead of the industry norm of 50,000 cycles.
Godrej’s customers in defence, aerospace and nuclear application industries request audits during the manufacturing process to ensure quality measures are being maintained and will insist on seeing ballbar certificates for the machines. Nayak explained, “Renishaw has helped Godrej to redefine quality norms, boost in-house capabilities, competence & confidence and helped reduce costs.”
Beyond savings to revenue generation
Die and mould customers choose Godrej because of the long lifespan of its dies resulting from tightly controlled quality parameters. The customer demand for high quality and precision measurement prompted the company to provide laser and ballbar certifications. Now, Godrej offers calibration services to others, generating an additional revenue stream. Its manufacturing facility is equipped with state-of-the-art CNC, EDMs and jig boring machines. “High precision calibration of these machines with a Renishaw laser or ballbar is key to quality and reliable performance,” Nayak signed off. ☐Courtesy: Renishaw
QC20-W ballbar test set-up
in Godrej manufacturing facility
30 EM | S ep 2021
ROBOT ICS A P P L I C AT ION
Passenger to freighter retrofitting aircraftThe robust demand for converted freighters has been driven by a strong cargo market, a silver lining for the airline industry during the coronavirus pandemic. The scarcity of passenger-jet belly size and flourishing e-commerce has furthered the freighter market. However, an aircraft conversion is technically very complex. Reinforcing the floor structure of passenger aircraft to accommodate heavier payloads is one such labour-intensive process that involves drilling thousands of holes. This case study talks about how the spindle for the robot cell that comes from Zimmer Group came to the rescue of Helios Applied Systems and also supplied a storage station for the wooden shank tapers.
The coronavirus pandemic has disrupted supply chains worldwide, paralysed production lines and led to metropolises worldwide being in lockdown. The economy has been in a state of emergency for over a year. The airline industry has been hit particularly hard. Thousands of flights have been cancelled, in some cases entire fleets of aircraft have been parked and mothballed – air traffic has been affected worldwide on an unprecedented scale due to the corona crisis.
The measures to contain the corona pandemic are affecting not only passenger traffic but also airfreight (including airmail), because passenger aircraft actually transport a large proportion (about 50%) of airfreight. Profiteers of the current crisis are cargo airlines/mixed carriers (freighters and PAX
aircraft) and charter airlines, which are very likely to look back on record results in these times. Driven by the air cargo boom and the growth of online trade, the need to convert unused passenger aircraft into freighters is, thus, increasing. This is described by the term ‘Passenger to Freighter’ (P2F). Based on the current market, analysts expect growing demand in this area. In addition to opportunities for aircraft manufacturers, maintenance companies, airlines and leasing companies also benefit from the conversions.
Complex aircraft conversion
However, an aircraft conversion is technically very complex.
APPL ICAT ION ROBOT ICS
31EM | S e p 2021
It requires highly skilled technicians and a multitude of parts whose processing must be synchronised to ensure a smooth process and timely completion. Only a few years ago, many work steps were carried out manually, but today, even in the aircraft industry, more and more so-called Maintenance/Repair/Operation (MRO) processes are being automated. Reinforcing the floor structure of passenger aircraft to accommodate heavier payloads, for example, is one such labour-intensive process that involves drilling thousands of holes. This is where the aerospace division of Singapore-based ST Engineering Aerospace, an aircraft conversion specialist, relies on the support of a robotic cell. For this purpose, the company has been working with Helios Applied Systems, also based in Singapore, since 2019 to automate such complex processes.
Colleague robot helps
The robotic cell drills dozens of holes in the floor grilles of Boeing’s 767-300ER aircraft at STE Engineering’s plant at Paya Lebar, Singapore to convert it into a cargo plane in accordance with Boeing’s STC*. To do this, the robot cell moves along the floor structure so that the robot can drill the corresponding holes according to a predefined plan. The cell is located in a hangar that is conveniently adjacent to the converted aircraft. The robotic cell consists of a hydraulically liftable, movable platform, a Yaskawa robot with a payload of 180 kg, a special image processing system developed by Helios and a high-frequency spindle with six kilowatts and a hollow shank taper (HSK) for fast automatic tool change.
One spindle makes the difference
The air-cooled spindle of the HFL145 series, which has a nominal torque of 4.9 Nm and a maximum speed of 24,000 rpm, was supplied to Helios, complete with all the necessary cables and with a frequency converter. This is particularly suitable for precise positioning tasks with integrated safety technology (STO) and for operations at low or high speed. In addition, the inverter offers optimum performance or power yield with perfect matching of spindle and frequency inverter.
In order to be more flexible for future applications, the spindle was mounted directly on a semi-standard tool changer (ROB000117 - also from Zimmer Group). The HSK tapers and tools themselves were provided on site by Helios. Helios uses the Zimmer spindle with a fieldbus connection (EtherCAT) and also received the complete parameterisation from the automation expert from Rheinau.
Successful cooperation
“Due to the rigid construction and the very smooth running of the spindle, even at higher speeds, the drilling result is very good. You have to consider that these parts are light and not completely flat, so the vision recognises the position and angle of each hole,” says Sunil Raibagi, Project Manager & Vice President – Business Development & Strategy, Zimmer Group. The customer, Helios is also satisfied: “We appreciate Zimmer Group as a long-standing partner and are convinced of the qualities of the spindle. The smooth, no-vibrating spindle we could mount a camera on EOAT which is a success of a project.
Busy in the future
While the robot is currently focused on drilling floor grids, the STE Engineering team is working with Helios to program the machine so that it can also be used to set countersunk rivets. “We believe the robots can handle these types of processes well,” said Hui Fung Lee, SVP and Head of innovation & continuous improvement, ST Engineering Aerospace.
In the coming months, the robot will also be programmed at STE Engineering to perform other functions and work on other aircraft models, including Airbus freighter conversions. “We know that the P2F process is very complex, and many people are needed for the whole conversion process,” Lee explains and adds, “Therefore, we are constantly looking for ways to improve our productivity.” Tasks that lend themselves to automation tend to be standardised and very repetitive, he further conveys. Starting next year, ST Engineering plans to automate the drilling of floor grilles for the A321-200P2F conversion programmes it owns through EFW, a joint venture with Airbus. ☐Courtesy: Zimmer Group
The robot cell moves along the floor structure so that
the robot can drill the corresponding holes according
to a predefined plan
32 EM | S ep 2021
ART IF IC IAL IN T E LL IGE N C E SPE C I AL F E AT URE
Industry 4.0 and AI – Driving flexible factories of tomorrowAs the world becomes progressively automated, the Internet of Things (IoT) is already changing the technology world. The use of Artificial Intelligence (AI) makes this more obvious, with all the advantages offered by Industry 4.0. AI has taken centre stage when it comes to recent innovations in the industrial revolution and for manufacturers, this technology proves to be particularly significant. This article talks about the integration of AI into manufacturing, how engineers with domain knowledge will be the most needed for future factories and how production line flexibility will be accelerated by Industry 4.0 & AI technologies.
The industrial world is changing with the emergence of smart industry. The consumers of today have been demanding more customisation & individualisation and to consciously handle resources as we start thinking about the impact on the environment. This trend has been forcing companies to embrace flexibility in their production lines as they are scaling up their large scaled customised production. Today’s machines are set up in a fixed, inflexible manner on the shop
floor—commissioned, parameterised and tuned for one specific product produced repeatedly for months or even years. The manufacturing lines of tomorrow need to shorten production iteration cycles while maintaining their flexibility.
While developments around Industry 4.0 and Artificial Intelligence (AI) have been rapidly widening the limits of what is possible in the industrial world, engineers and scientists are facing the challenges of managing the growing
R Vijayalayan, Manager, Automotive Industry Field Application Engineering Team, MathWorks India
33EM | S e p 2021
SPEC I AL F EATURE ART I F I C I AL I NTELL IGENCE
complexity of software and an ever-increasing amount of data to create new business models and become market leaders.
Robotics – Adding flexibility to the production
With Industry 4.0, the vision must eventually come true to meet the requirement of full individualisation in production. To meet this, tomorrow’s production lines must be flexible – built from multiple mechatronic modules that can easily be rearranged, with more and more robots or ‘cobots’ (collaborative robots working hand-in-hand with human workers) and an AI that parameterises and tunes the machines according to the next – individualised – good that is manufactured on the line.
AI in manufacturing
AI has the potential to become a game changer for the manufacturing industry. This will go far beyond use cases like predictive maintenance, vision-based quality inspection, production optimisation that are already a reality today. AI-based systems will be in the centre of tomorrow’s flexible production facilities, orchestrating machines and flexibly rearranging entire production lines while minimising the consumption of energy and other resources. Several companies, including MathWorks, have been developing tools that help train and deploy AI algorithms aimed at achieving certain economic benefits.
Integration of AI into manufacturing
More engineers are realising that modelling is an important step in the AI workflow, but the model is not the end of the journey. The key element for success in practical AI implementation is uncovering any issues early on and knowing what aspects of the workflow to focus time and resources on for the best results—and it’s not always the most obvious steps.
Most often, AI is only a small piece of a larger manufacturing
system, and it needs to work correctly in all scenarios with all other working parts of the continuously running manufacturing line. This includes data collected from sensors on the equipment through industrial communication protocols, like OPC UA as well as other pieces of the machine software, such as control, supervisory logic and HMI.
The AI-driven workflow
For full integration, engineers also need to focus on multiple aspects of AI. Beginning with data preparation, then modelling, followed by simulation and test, and then finally deployment, this four-step workflow allows for an AI model to be successfully integrated into a 24x7 manufacturing process.
Engineers with domain knowledge and knowledge to integrate technologies will be the most needed for future factories. Engineers have professional knowledge of the industry, equipment, processes etc., (commonly referred to as domain knowledge) and with tools for data preparation and designing models, they can get started even if they’re not AI experts, allowing them to leverage their existing areas of expertise. In this process, MATLAB provides a wealth of applet applications that can help engineers with specialised knowledge to quickly integrate new technologies, such as AI, into their practical work.
In summary
• Future manufacturing set-ups will be more flexible• Production line flexibility will be accelerated by Industry
4.0 and AI technologies• Integration of AI into manufacturing can be made
smooth by focusing on the four-step AI workflow• Engineers with domain knowledge who can integrate new
technologies into their practical work will be the most needed for future factories ☐
AI-driven system design workflow
34 EM | S ep 2021
EVENT R EP ORT
The impact of 3D Printing or Additive Manufacturing (AM) on the industrial manufacturing market is often ardently discussed. At the same time, the industry is making speedy developments and it won’t be long before we see the technology meaningfully making its mark on global supply chains. With this background, Publish Industry India recently organised the Virtual Additive Manufacturing Congress, with Autodesk Fusion 360 & Phillips Machine Tools as Technology Partners and AMSI as Association Partner. The experts at the summit talked about AM for sustainable manufacturing, development of 3D Printing applications, the impact of Additive Manufacturing on the supply chain and more. A post-event report…
With increasing global competition & changing global standards, manufacturers are becoming aware of the strength & potential of Additive Manufacturing (AM) in responding to market challenges & industry transformations and meeting tough performance standards. There is a continuous aim to bring down costs, achieve faster speed to market, and most importantly, reduce the impact of manufacturing on the
3D Printing - Its impact on manufacturing & supply chain operations
environment, where AM plays a pivotal role. In this context, Publish Industry India recently organised the Virtual Additive Manufacturing Congress, with Autodesk Fusion 360 & Phillips Machine Tools as Technology Partners and AMSI (Additive Manufacturing Society of India) as Association Partner. The summit addressed common challenges, discovered opportunities and found ideas to accelerate the use of Additive Manufacturing.
Juili EklahareFeatures [email protected]
35EM | S e p 2021
REPORT EVENT
Opportunities & challenges in AM
The summit began with the opening address by Dr L Jyothish Kumar, President, Additive Manufacturing Society of India. He focused on the AM opportunities & challenges in India. For instance, in the healthcare sector, AM has the potential to fabricate biomedical implants, prosthetics, skin & tissues and intricate organs. Coming to the challenges, he spoke about the challenges to adopt Additive Manufacturing. “As industrial AM is still in the early stages of development, there is a lack of formal AM industry standards,” Kumar observed.
This was followed by a technology presentation by Vipul Agrawal, Technical Specialist, Autodesk Fusion 360. He focused on three technologies – Parametric Mesh Modelling, Additive Printing & Generative Design. Starting with Parametric Mesh Modelling, Agrawal showed the viewers a sample of a mesh file and its repairing being tough. Through his presentation, he pointed out an unwanted area and a part that needed to be flattened, which can be easily done with the mesh modelling technique in Fusion 360. Similarly, he spoke about new applications in Additive Printing & Generative Design.
Fireside chat
It was then time for the fireside chat and Surendra Vaidya, EVP & Business Head, Godrej Aerospace and Dr Dheepa Srinivasan, Chief Engineer, Pratt & Whitney, United Technology Corporation were a part of this chat. The chat was moderated by Shekhar Jitkar, Chief Editor, Publish Industry India. The session analysed the role of AM in the future of manufacturing and how strategies & business models will evolve further with this.
Jitkar started with Vaidya, and asked him how he sees the acceptance and use of AM technology in the aerospace sector and if he sees any challenges in it. “There are many processes required after one does the 3D Printing. I don’t see 3D Printing as a replacement,” Vaidya put across and added, “I look at 3D Printing as a technology changeover, where the combination of materials can be added into one part and the number of parts can be reduced down to only one part. This will give designers far better flexibility once we stabilise the process.”
Emerging trends in 3D Printing
Coming to Srinivasan, who has been in the R&D profession for long and also the inventor & developer of many new technologies, she was asked to highlight some of the emerging trends and new applications in AM which the manufacturing industry can be benefitted from. Srinivasan mentioned that composite materials have a couple of players across the world who have marched ahead. “Another one is ceramic materials and hybrid manufacturing,” Srinivasan asserted and went on, “These areas are where emphasis is being made in terms of R&D.” Sharing
his thoughts on bringing down cost, Vaidya cited that for any part or innovation that has to be brought into the market, one first has to do a lot of protos and lab tests. He then quoted, “Another important aspect in 3D Printing is that while any product requires sheets, plates, tubes, etc, in 3D Printing, one requires to procure only a different combination of powders or wires and print anything.” Further, Srinivasan claimed that the beauty of additive is that we do have a benchmark in the conventional process. As for the repeatability, reproducibility issues, there was not as much data available four years ago and everybody was starting with a coupon-level test. Today, we don’t need that coupon-level test; one can straightway start with the design criteria.
Complementing conventional manufacturing with AM
Later on, there was a technology presentation by Sumeet Bengeri, Head, Phillips Additive India. He spoke about complementing conventional manufacturing with Additive Manufacturing. Giving examples of how 3D Printing is complementing traditional manufacturing, Bengeri gave an instance of customers. One such customer is Lean Machine that used 3D printed parts on a vice or soft jaws, with complex geometries involved. Going forward, he showed the audience some images where Guhring adopted the Markforged machines to implement the special tools using 3D Printing.
It was then time for the panel discussion on ‘How 3D Printing will impact traditional manufacturing & supply chain’. The revered panellists were Kripal Bedi, Head of Design, Sridevi Tool Engineers; Dr Vishwas Puttige, Business Head, amace Solutions; Ashok H Varma, Advisor to Board of Directors, xBeam 3D & Owner, E-FESTO-3DP; Raja Sekhar Upputuri, Co-founder & CEO, think3D.in and Swati Suman, Founder, The Art of Making Foundation & State President, 3D Printing Council. The discussion was moderated by Juili Eklahare, Features Writer, Publish Industry India.
Cost, time & properties
The concept of digital inventory is a big talking point, in terms of the digital transformation AM brings. So, the first question was put to Upputuri, asking him the ultimate checklist for a good digital inventory strategy. To this, Upputuri disclosed that it ultimately boils down to cost, time & properties. “Firstly, one needs to have the repository of all the components,” he expressed and went on, “Secondly, one needs to study what can be 3D printed, what is recommended to be 3D printed and what can only be 3D printed.”
Eklahare went on to ask Upputuri how we can help build more resilient supply chains in the future through 3D Printing through this period. He revealed, “Whenever there is such a gap in finishing the stock, we can use 3D Printing to manufacture for
36 EM | S ep 2021
EVENT R EP ORT
that particular time period and then later go for mass manufactured components.”
3D Printing impacting traditional manufacturing
Following this, Bedi went on to share his thoughts on how 3D Printing will impact traditional manufacturing and the supply chain. Coming from the plastic mould making industry, he spoke from the user perspective. “As for 3D Printing impacting traditional manufacturing, we are getting much better product designs for mould making or for tooling because all the testing, virtual assembly, physical assembly, prototyping, etc has been done in the design stage. People are really confident about their designs. This is an indirect way in which 3D Printing has affected us in traditional manufacturing.”
Stating his thoughts on the same point as Bedi, Varma told the viewers that the number one benefit with Additive Manufacturing is reduction in lead time. He communicated to the audience, saying, “The number one benefit for supply chain that I have learnt from about 30 company interactions now is reduction in inventory. The other thing about supply chain mitigation is that you reduce the obsolescence of spare parts. Also, if you can print in-house, in-country, on location, then you protect yourself from the embargoes that a government can put on you.”
The post-processing angle
Eklahare then turned to Puttige asking him what are some
of the current challenges companies face when it comes to post-processing specifically, in 3D Printing. Puttige implied,
“When you get to tolerances close to what you would want on a conventionally made part and finish it to the tight tolerances that are there, you have to understand the machinists’ concerns, what sort of dimensions & tolerances are achievable and what you have to do in terms of correction to allow certain things to be achieved as post-processing. Besides, something that people do end up missing out is supports – removing the supports is a challenge.”
Skills in 3D Printing
Moving to the skills aspect of 3D Printing, Suman was asked if there is a skill gap within AM and if yes, what is being done to address it. She pronounced, “A few colleges in India, like COEP Pune, are providing post-graduation degrees in Additive Manufacturing, while the rest, like IIT Kanpur, are providing short-term courses. There should be a curriculum standard in all the universities, just like we have for mechanical engineering or electronics engineering. There should be a demand for the skills required and then people can have a channel for it.”
The summit was an insightful one, giving in-depth insights on 3D Printing technology and where it’s taking the manufacturing world. The advice, inputs and thoughts put across were practical and logical, proving useful for the industry, where companies are likely to develop more curiosity & interest in the technology and implement it in their organisations. ☐
Shekhar Jitkar, Chief Editor, Publish Industry
India, in conversation with Surendra Vaidya,
EVP & Business Head, Godrej Aerospace
and Dr Dheepa Srinivasan, Chief Engineer,
Pratt & Whitney, United Technology
Corporation during the fireside chat
Juili Eklahare, Features Writer, Publish
Industry India, moderating the panel
discussion on ‘How 3D Printing will impact
traditional manufacturing & supply chain’
EM | S e p 2021 37
NEWS TECHNOLOGY
Decentralised frequency inverter
Nord Drivesystems recently supplied application-optimised drive systems for
compact mobile machine systems like pumps or fans up to 22 kW. For variable
speed operation of such machines that often
have only one or a few drive axes, the NORDAC
FLEX SK 200E frequency inverter can be directly
mounted on the motor or close to the motor at
the machine. The decentralised frequency
inverter is suitable for applications, such as
mobile conveying or dosing in process
engineering, and applications with similar
requirements. The inverter generates the control
voltage itself and can be easily & locally
controlled and operated via switch and rotary
potentiometer. Using the inverter's integrated PLC, the device can perform
minor logic functions autonomously. The inverter demonstrates its high
operational flexibility particularly with saving synchronous motors. In dosing
application, the NORDAC FLEX can implement exact dosing requirements via
the integrated POSICON positioning function. Frequency inverters from the
NORDAC FLEX series are characterised by their high precision regulation.
Extending into low-speed ranges, the drive control prevents strong turbulences.
Email: [email protected] | Tel: +91-20-3980 1200Nord Drivesystems | Pune
NORDAC FLEX SK 200E
frequency inverter
Double-edged cutting inserts
Walter Tools recently expanded its DX18 parting off and recessing range.
As with the G4014, the company is also using the double-edged DX18
cutting inserts with their own positive
engagement design for the new
additions in the form of the G4041
deep parting blades and G4011
monoblock shank tools (with and
without precision cooling,
respectively). This reliably prevents
lateral movement of the inserts in the
insert seat, therefore increasing the
indexing accuracy, stability and process reliability. Including G4041-P
deep parting blades and Walter Capto™ G4011-P tools for universal
application, the range therefore now covers insert widths from 2-4 mm
and cutting depths up to 10 mm and 17.5 mm, respectively. The potential
application ranges given by them are all machining operations, from
parting off and grooving with a flat groove base through to universal
application for recessing and dynamic recessing. Regardless of the tool,
users from all industries can benefit from the high level of process
reliability of the positive-locking DX18 cutting inserts and the high degree
of productivity due to improved chip breaking.
Face mill for roughing to semi-finishing operations
WIDIA™ recently announced the release of the M1600 face mill for roughing
to semi-finishing operations in steel, stainless steel, cast iron and nodular
iron materials. With 16-cutting edges and
a smart insert design, the M1600
performs in various machining conditions,
including low-power machines, unstable,
non-rigid set ups, long overhangs, weak
machines or weak fixture conditions. The
M1600 has one universal insert geometry
in three versatile grades: WP35CM,
WK15CM and WU20PM. The WP35CM grade targets all types of steels, while
the WK15CM grade is designed for cast iron materials and performs best in
dry applications but can also be used in wet conditions. The universal
WU20PM grade can be used for the machining of steel, stainless steel and
high-temperature alloys in both dry and wet applications. The ‘smart’ insert
design features a seating surface below the cutting edge that promotes
smooth chip flow and reduces cutting forces on the tool. The insert also has
a curved cutting edge and is axially positive, resulting in reduced power
consumption. These key design features coupled with 16 cutting edges
make M1600 an economical face milling option. M1600 face mills are
available in six metric diameter ranges between 50 mm and 160 mm.
Email: [email protected] | Tel: +91-20-30457346 Email: [email protected] | Tel: +1-724-539 3877Walter Tools | Pune WIDIA Products Group | Pennsylvania, USA
DX18 parting off & recessing range
M1600 face mill
Machinery and processes monitoring module
B&R Industrial Automation recently presented a new gate measurement
module for efficient machine and process automation. With a new bus
controller, the company has added a gate measurement module to its portfolio
for efficient monitoring of machinery and
processes. The new gate measurement
module joins the X67 line up to help keep
manufacturing processes consistent and
reduce the rate of rejection, thus increasing
both quality and productivity. By measuring
the duration of switching operations with
extreme precision, the module is able to
detect even the slightest deviations, which can point to component wear,
changes in temperature or other environmental factors. The IP67-rated
module stands up to the most demanding conditions. It has six digital outputs
with readable status and six digital inputs. The digital channels can be
configured in pairs to perform gate measurement with a resolution of 100 µs
directly on the module. Gate measurement can be triggered on positive or
negative edges. The device also has an analogue input with configurable filter
functions. Its digital outputs are protected against overload and short-circuits.
The module is connected to the machine network via POWERLINK.
Email: [email protected] | Tel: +91-20-4147 8999B&R Industrial Automation | Pune
Gate measurement module
38 EM | S ep 2021
H IGHL IGH T S CO MPAN Y INDEX | IMPR INT
» Industrial Maintenance With the growing competition for manufacturing, many companies are exploring ways to gain competitive advantages with respect to cost, service, quality, etc. Industrialists are now starting to realise that effective maintenance management contributes to overall organisational productivity. The forthcoming edition reconnoitres the evolution and future of industrial maintenance.
Highlights - October 2021
COMPANY INDEXName . . . . . . . . . . . . . . . . . . . . . . . Page
ASSOCHAM . . . . . . . . . . . . . . . . . . . . . 09
Autodesk Fusion 360 . . . . . . . . . . . . . . . 34
B&R Industrial Automation . . . . . . . . . . . 37
Blaser Swisslube Solutions . . . . . . . . . . . 07
Central Manufacturing Technology
Institute (CMTI) . . . . . . . . . . . . . . . . . . . 08
Dassault Systèmes . . . . . . . . . . . . . 09, 14
EMotorad . . . . . . . . . . . . . . . . . . . . . . . 12
ExxonMobil Lubricants . 11, Back Inside Cover
German Machine Tool Builders’
Association (VDW) . . . . . . . . . . . . . . . . . 10
Name . . . . . . . . . . . . . . . . . . . . . . . Page
Godrej & Boyce . . . . . . . . . . . . . . . . . . 08
Hexagon . . . . . . . . . . . . . . . . . . . . . . . 08
Indian Railways . . . . . . . . . . . . . . . . . . . 08
Jyoti CNC Automation . . . . . . . . . . . . . . 01
Komaki Electric Vehicle Division . . . . . . . . 06
Lakshmi Machine Works . . . Front Inside Cover
MathWorks India . . . . . . . . . . . . . . . . . . 32
National Aerospace Laboratories (NAL) . . . 09
Nord Drivesystems . . . . . . . . . . . . . . . . . 37
Objectify Technologies . . . . . . . . . . . . . . 24
Phillips Machine Tools . . . . . . . . . . . . . . 34
Quaker Houghton . . . . . . . . . . . . . . . . . 25
Name . . . . . . . . . . . . . . . . . . . . . . . Page
QVI India . . . . . . . . . . . . . . . . . . . . . . . 23
Renishaw . . . . . . . . . . . . . . . . . . . . . . . 28
Sandvik . . . . . . . . . . . . . . . . . . . . . . . . 09
Schneider Electric . . . . . . . . . . . . . . . . . 08
SKF India . . . . . . . . . . . . . . . . . . . . . . . 18
Ultraviolette . . . . . . . . . . . . . . . . . . . . . 08
Varroc Engineering . . . . . . . . . . . . . . . . 20
Walter Tools India . . . . . . . . 37, Back Cover
WIDIA Products Group . . . . . . . . . . . . . . 37
Zimmer Group . . . . . . . . . . . . . . . . . . . 30
» Cutting ToolsHigh-end cutting tools with outstanding performance and long-life run are essential in manufacturing. All cutting tools have multiple axis points of motion, which drive them around and through the workpiece, thus removing material. The following issue explores the know-how of how to maximise competitive advantage and boost ROI through cutting tools.
Publisher / Chief Editor Shekhar Jitkar [email protected]
Features Writer Juili Eklahare [email protected]
Content Developer (Online & Print) Namrata Singhania [email protected]
Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 [email protected]
Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 [email protected]
Alok Kumar (Sr Manager – South) Bangalore Contact: +91 8861009443 [email protected]
Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) [email protected]
Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 [email protected]
Design & Layout Tarun Kumar Pyne Design Head (Print & Web)
Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: +91-7410006435/36
Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Shekhar Jitkar (Publisher / Chief Editor)
Subscription Cover Price: `100 Annual Subscription Price: `1000 [email protected] Tel: +91-7410006435/36
Printing MARS REPRO SOLUTIONS, C2/12, Shivtara Garden, Near Gananjay Society, Kothrud, Pune 411038
Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of the magazine contents is only allowed with written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.
Internet https://industr.com/en/
Digital edition https://www.industr.com/en/e-paper
IMPRINT
» Coolants & LubricantsThe manufacturing industry has been using cutting fluids in metal cutting operations for long. With the cutting operations becoming more severe, cutting fluids have become even more complex. The upcoming issue will investigate the future of coolants, lubricants and metalworking fluids in the Indian manufacturing industry.
» Machining CentresSince the past few years, there have been various developments in high-speed machining and machining centres. It is essential to understand the thriving technologies in machining to cope with the future and to continue having a strong market presence. The next issue will peep into the key drivers of machining centre products in the manufacturing industry.
RNI No. MAH/ENG/2010/34603