Manufacturers can cut internal and external forms rapidly and accurately into workpieces with rotary broach tooling and can produce precise hexes, squares, serrations, splines, and other custom shapes on CNC machines.
An internal live spindle holds an end-cutting broach tool at a 1° angle. In a lathe, the rotary broach toolholder is stationary while the spindle and rotary broach rotate 1:1 with the workpiece. Driven by the workpiece, the rotary broach tool’s corners continually change contact points on the workpiece, wobbling while it cuts each corner of the form rapidly.
In a mill or vertical machining center (VMC), the toolholder’s body rotates in the machine spindle while the holder’s spindle and broach remain stationary, creating the wobbling action while the rotary broach tool’s corners continually change contact points on the workpiece. Form sizes can be broached up to 2" in aluminum or brass and 1" in steel, with depths up to 1.5x the form’s minor diameter.
The connectable ZeroAct workpiece positioning system offers manual and electric zero-point clamping in milling, inspection, and finishing.
Modules rapidly and simultaneously open and close, generating 15kN clamp force. Up to three 40mm x 150mm x 150mm clamping modules can be attached in a row with connecting pins from 5mm to 105mm. By actuating the first unit, all three units clamp simultaneously.
An electric e-motion version uses 24V power that operates with a built-in electro-motor for fully automated loading and unloading. Pull-down pins are interchangeable with the manually operated ZeroAct and other APS/WPS zero-point systems.
Modules provide repeat accuracy of <0.005mm, are sealed against corrosion, and feature built-in air cleaning so the clamping system’s support surface remains clean and free of chips.
The 8L lathe can fill turning needs in a variety of spaces. Rigid enough to cut plastic, stainless steel, or titanium, it can be equipped with an integral coolant tank, separate chip drawer, storage drawers, side shelving, and a tool holder/tool kit.
The lathe’s 5C spindle accommodates parts up to 1" diameter, and users can add a 3- or 4-jaw chuck to cut stock up to 8" in diameter.
Intuitive conversation lathe programming PathPilot software lets operators do rigid tapping and leverage built-in Dropbox support for transferring programs.
Anaheim, California-based Cadence Aerospace, a provider of complex aerospace components and assemblies for commercial and defense customers, appointed Kevin W. Martin as CEO for the company’s engines systems segment. Martin will also continue as Cadence CIO, reporting to Julian Guerra, Cadence Aerospace CEO and CEO for the company’s aerostructures segment.
Martin will oversee Engines Systems operations at Cadence’s Aero Design & Manufacturing Inc. in Phoenix, Arizona; B&E Precision Aircraft Components in Southwick, Massachusetts; and Tell Tool in Westfield, Massachusetts.
Martin succeeds Bob Quaglia, who is retiring as CEO of the Cadence Engines Systems segment. Quaglia has been appointed as a member of the Cadence Board of Directors.
Solar Atmospheres, Kittyhawk partner
Heat-treating specialists Solar Atmospheres of California and hot isostatic pressing (HIP) specialists Kittyhawk have formed a strategic partnership. Solar Atmospheres and Kittyhawk are both Nadcap, ISO9001, and AS9100 certified.
Image source and copyright: Lockheed Martin. Used with permission.
Fastems to laser clean F-35 wing components
Two Fastems automated structure laser cleaner (AutoSLC) units are joining the F-35 Lightning II wing assembly line in Fort Worth, Texas. The project is estimated to be completed by the end of 2021.
The AutoSLC robotized system uses a laser ablation scan head to automatically remove primers and other protective coatings from F-35 wing components, providing pristine surfaces to which nutplates can be mechanically bonded without using rivets. Previous methods of coating removal entailed time-consuming manual sanding and solvent wiping, which yielded inconsistent bonding results. Automated image processing gathers information on quality anomalies for traceability and process improvement, allowing Fastems’ AutoSLC system to process more than 3,000 drilled holes while reducing touch labor hours.
“The path to successful cooperation with Lockheed Martin has been open and frequent collaboration from the very beginning and, together, developing a clear unified vision for the project. This has made processes and decision making much faster and has allowed us to deliver and even exceed the expected results,” Fastems CEO Mikko Nyman says.
“At Lockheed Martin, we test and validate any new complex solution from the initial concept, through design and build, and after delivery. The fact that Fastems understands and shares this attention to detail positions them well to deliver a quality product at every phase,” says Steve Callaghan, vice president, F-35 Business Development and Strategic Integration.
Moog acquires Genesys Aerosystems
Elma, New York-based Moog Inc. purchased Genesys Aerosystems and its S-Tec Corp. subsidiary in December. Genesys provides flight control systems for military and commercial aircraft and will keep its locations in Mineral Wells, Texas; and Anchorage, Alaska, as part of Moog’s Aircraft Controls segment.
Genesys specializes in advanced avionics suites; synthetic vision navigation; digital radios; air data, attitude, and heading reference systems (ADAHRS); global positioning systems (GPS); compact sensors; and autopilots for fixed- and rotor-wing aircraft.
Moog’s precision control components and systems control military and commercial aircraft, satellites, space vehicles, launch vehicles, missiles, automated industrial machinery, marine, and medical equipment.
AMGTA research paper on sustainable AM
Departments - 3D/Additive Manufacturing
SDK connects AM to the smart factory; 6K Additive expands metal powder production team; EOS, Texas A&M partner on AM professional development.
The Additive Manufacturer Green Trade Association (AMGTA) published its first commissioned university research project, a literature-based systematic review of the environmental benefits of metal AM. The paper, “State of Knowledge on the Environmental Impacts of Metal Additive Manufacturing,” was written by Dr. Jeremy Faludi from Delft University of Technology (TU Delft) and Dartmouth College and Corrie Van Slice, a former senior research engineer at Faludi’s lab at Dartmouth. Van Slice is now a manufacturing sustainability research engineer at TU Delft. According to its authors, the report synthesizes existing academic literature comparing environmental impacts of metal AM with conventional manufacturing methods and provides context with impacts of common metals and processing methods found in a materials database.
Key takeaways:
While AM generally has much higher carbon footprints per kilogram of material processed than conventional manufacturing (CM) when considering the direct manufacturing process itself, impacts depend greatly on part geometry
The need for additional life cycle assessment (LCA) studies to quantify environmental impacts to definitively compare metal AM to CM; especially direct comparisons of AM to machining, and for binder jetting and directed-energy deposition (DED); LCAs should also include more of the product life cycle
SDK connects AM to the smart factory
Stratasys software tools integrate its 3D printers in production environments with the factory floor via the GrabCAD Software Development Kit (SDK). Each SDK package includes application programming interfaces (APIs), documentation, and code samples for development partners and manufacturing customers to establish two-way connectivity between Stratasys FDM 3D printers and enterprise software applications. Users can integrate, manage, and support additive manufacturing (AM) for production of end-use parts.
Initial partners for the GrabCAD SDK program include Link3D and Identify3D.
The first two available SDK packages enable users to integrate with GrabCAD Print software and Stratasys manufacturing systems including the F900, Fortus 450mc, and F123 Series of FDM 3D printers.
6K Additive expands metal powder production team
Dr. George Meng, John Meyere, Joe Muha
6K and 6K Additive, developer of additive manufacturing (AM) powders derived from sustainable sources, has hired AM experts who bring extensive knowledge in quality, powder manufacturing, and process as the organization begins production of its onyx line of AM premium powders in its recently commissioned 40,000ft2 lights-out facility.
Recent additions to the team include:
Dr. George Meng, Director of Process for Additive
John Meyer, Director of Technology, AM Products
Dave Novotnak, Production Process Manager, AM Products
Joe Muha, Quality Manager, AM Products
EOS, Texas A&M partner on AM professional development
Metal and polymer 3D printing technology supplier EOS has partnered with Texas A&M University (TAMU) to provide a professional development program in industrial 3D printing. Using virtual learning with conventional training methods, the additive manufacturing (AM) program offers a hands-on, expert-led training program to meet evolving industry needs and challenges.
In concert with EOS’ applied engineering group Additive Minds, the TAMU Engineering Experiment Station program takes a deep dive into the latest powder bed AM processes – such as direct metal laser solidification (DMLS) and selective laser sintering (SLS), as well as an understanding of other AM processes, materials, design, case studies, best practices, and troubleshooting. The certificate-level training program was developed by subject matter experts from TAMU (Dr. Alaa Elwany, associate professor of industrial and systems engineering and director of the metal AM laboratory) and EOS’ Additive Minds Consultants Maryna Ienina and Dr. David Krzeminski.
Keeping drones aloft after engine failure
Departments - 1 Last Look
Robotics researchers show how quadrotors can be saved from falling if one rotor fails.
Algorithms combine sensor information to track the quadrotor’s position in the environment.
Photo credit: UZH
Aircraft can continue to fly if an engine fails however, for quadrotor drones – those with four propellers – such a failure poses a serious problem. With only three working rotors, drones lose stability and inevitably crash unless an emergency control system is used.
Researchers from the University of Zurich and the Delft University of Technology have developed a system to overcome that – if a rotor suddenly fails, built-in sensors can feed data to autonomous control systems to stabilize the drone and keep it flying.
“If a rotor fails, the drone begins to spin around like a ballerina,” says Davide Scaramuzza, head of the Robotics and Perception group at the University of Zurich (UZH) and the National Rescue Robotics Grand Challenge research unit of the Swiss National Science Foundation (SNSF), which finances the study. “The rapid rotation causes conventional controls to fail. Unless the drone has access to very precise position measurements.”
As soon as the drone starts to spin, it can no longer determine its position in space and crashes.
One possible solution is to give the drone a reference position using GPS. However, corresponding signals cannot be received in all environments. Rather than relying on a GPS measurement, the scientists use the visual information from multiple built-in cameras.
Researchers equipped quadrotors with standard cameras that recorded several images per second at a constant speed and event cameras with independent pixels only activated by a noticeable change in light. The team’s algorithms combine information from both sensors to track the quadrotor’s position. The on-board computer controls the drone while it flies with only three working rotors.
Tests showed that both types of cameras work well in normal lighting conditions.
When a rotor fails, the drone starts spinning around like a ballerina.
“However, when the light decreases, standard cameras show motion blur, which ultimately causes the drone to crash. The event cameras, on the other hand, work well even in very little light,” says first author Sihao Sun and postdoc in Scaramuzza’s laboratory.
The scientists believe that their work can improve the flight safety of quadrotors in areas where the GPS signal is weak or absent.
The researchers have made their controller and algorithm open source.
The Smart Flow solution will display real-time work-in-progress location, activity, priority, actions required and wait times.
Aerospace manufacturers must be aware of how technology is changing to be ready to adopt smart systems to compete at a national and global level. Smart factories gain clear visibility into process flows, and they are better able to manage the complexity of high-mix production.
Insights into how well work flows through operations allow business leaders to manage priorities if issues occur and they can make the necessary changes using process control.
What needs to happen to successfully install these systems and achieve a competitive advantage? James Crean, co-founder, president, and CTO of Crean Inc., says it’s about fully integrating three key aspects – people, processes, and technology.
“The technology is there, and it’s continuing to evolve very rapidly,” Crean says. “It’s critical to not just have a technology solution but a people solution and a process solution that goes along with that and is integrated. Technology is only one part of the equation.”
Photos courtesy of Crean Inc.
Keep the end in mind
When identifying how to adopt smart technologies, companies should develop a clear list of solid goals and objectives for specific projects.
“For business leaders who are implementing a smart factory, they need to understand that it takes an integrated approach with a cross functional team, and whether that includes outside experts or not, you’ve got to have the right folks on the team to begin with,” Crean says.
Smart factory transformation requires integrating people, processes, and technology at the same time. Crean says there can be a tendency to over-focus only on technology. To avoid this, companies need outstanding people, leading-edge technology, and modern, flexible process methods that deliver faster, establish competitive cost objectives, and target game-changing performance.
“The technology solution, in a lot of ways, is often the easiest part,” Crean adds. “But at the same time, it’s very easy to make mistakes in an ever-evolving technology space. Manufacturers must select the right technology and have a full understanding of what their goals are to ensure the technology is capable of achieving those goals.”
For example, Crean often helps clients with asset tracking. Many technology options track assets with radio frequency identification (RFID), Bluetooth low energy (BLE), ultra-wide band (UWB), magnetic loops, ultrasound, and cameras with machine learning.
Users must have the right expertise to make sure they select the right hardware tracking solution, and then they must choose the right software to deliver the data necessary for their environment. Every environment has its own factors that need to be considered.
Asset tracking helps organizations ensure the right things are in the right place at the right time, delivering data companies can use to significantly improve operational efficiency.
“You can also integrate the tracking and tracing of work in process with digital routers and digital work instructions,” Crean adds. “That can help you significantly improve productivity even more. And it can also ensure that you’re always delivering the right information to each operator as they work on a part or assembly. And, it also can help you with training and making sure the right operators are getting trained for the work they’re being asked to do.”
Process solution
With technology options chosen, company leaders must recognize that technology adjustments change the process itself. For instance, Crean works with clients who are looking to automate a manual inspection process. While they might expect that they’ll get a 10% or 20% improvement in productivity by automating their inspection process, there’s an assembly step that meters the rate of inspections at the same rate as production. Overall factory productivity won’t change even if managers record an increase in inspection productivity.
“You have to understand and analyze the process and have a solid capacity optimization analysis in hand for your process, as part of understanding how technology is going to improve your operation,” Crean says. “Otherwise, you’re wasting time, money, and resources.”
People
Successful people are at the heart of every successful business change or evolution, Crean explains. This includes corporate leaders and those at every level of their organization. Companies cannot successfully transform without skilled people who can focus on implementing that solution. People in the organization will evolve to use new tools and methods that the smart factory promises. Therefore, it’s important for technology solutions to be people centric, allowing workers to be brought into the solution as opposed to being left behind or viewed as victims of the solution.
Smart flow technology
Crean’s smart flow operating system integrates asset tracking and inventory management data to give users visibility into where everything is located to produce their product. It also gives insight into how to improve operations, delivering an essential level of control.
“We provide hands-on smart factory transformation consulting services, and we deliver an integrated, robust solution that’s tailored for the goals and objectives that our clients are trying to achieve,” Crean says. “We’ll use proven technology from a wide variety of technology providers throughout the world to help implement those solutions and ensure that they’re successful.”
Adapt to change
Focus should not only be on developing an optimized logistics operation. Demands will continue to shift as the industry moves forward, and there will be an increased need for customized products. Companies should be able to customize that product, produce it efficiently and effectively, and implement smart factory technologies that allow them to compete globally. This will position a company to be agile for the future as customers demand more customization.
“There’s a huge change that’s happening, and the future for business must include smart factory solutions in order for them to be able to compete.” Crean adds. “Are we ready for that change from my perspective? Despite a very clear uptick in interest by American manufacturers, they’re still far too many that have failed to recognize the competitive and national security imperative around retooling around these technologies.”
Pivoting is essential. Advanced tracking technology and the digital enterprise will allow companies to pivot quickly and keep their workers safe.
“Every successful technology transformation begins and ends with platform leadership, and a commitment at every level of the organization to be part of that integrated smart factory solution,” Crean says.
About the author: Michelle Jacobson is the assistant editor of AM&D. She can be reached at mjacobson@gie.net or 216.393.0323.
Integrated processes and systems
The ANCA Integrated Manufacturing System (AIMS) connects sequential processes in tool manufacturing, facilitating streamlined tool production and linking separate processes to each other and factory information technology (IT) systems.
AIMS offers functionality adaptable to each factory’s needs; from smaller scale, data-based options to the full AIMS setup across a series of machines. The server manages data flows between the elements of the AIMS system and established IT platforms, such as enterprise resource planning (ERP) systems. Users can choose from a suite of solutions to reduce production costs, resolve labor challenges, and integrate systems to improve product and process quality. AIMS transfers tools between operations with AutoFetch to fully automated tool measurement and process compensation using AutoComp, and managing data via the AutoSet hub.
DesignCore RS-6843AOP and RS-6843AOPU mmWave miniature radar sensors can implement many different algorithms to measure, detect, and track in robotics and industrial applications. The production-intent sensors feature a 1" cube form factor, heat-spreading metal body, and mounting tabs. They may be used with a PC or embedded platform for field testing, sensing evaluation, algorithm development, and application demonstrations.
Features include the TI IWR6843AOP, a single-chip 60GHz industrial radar sensor integrating a built-in DSP, an MCU, radar accelerator, and antenna array. The IWR6843AOP RF front end integrates a PLL, three transmitters, four receivers, and a baseband ADC. It covers 60GHz with bandwidths up to 4GHz and features 12dBm transmit power and 15dB noise figure or better.
The RS-6843AOP features a header for connection to optional baseboards or hosts providing additional interfaces and functionality. The interface includes I2C, SPI, GPIO, and UART connections. The main interface of the RS-6843AOPU version is a USB-C connector which can act as a power supply input and enumerate two serial UARTS, one for console and the other for processed radar returns or other algorithm output.
The ERA 4000 angle encoder series upgrades increase accuracy, ease of use, logistical flexibility, and are compatible with past models.
ERA 4000 angle encoders consist of a steel drum at various diameters with the 20µm, 40µm, or 80µm graduation on the outer diameter, and a scanning unit that reads the graduation. As an incremental system, reference marks are available as distance-coded or one per revolution.
Heidenhain Signal Processing (HSP) allows dynamic control of the LED, and the scanning unit learns of the signal quality coming back from the drum, then adjusts LED intensity on the next signal period. HSP operates in an analog way and increases the speed of the encoder system to 1MHz scanning, a 285% increase.
Two other upgrades to the scanning units are a status LED on the side of the scanning unit, providing unit status during mounting, and the addition of a smaller M12 connector which saves space and is more robust.
