Contrary to its compact size and relatively lesser cost and capacity, the Sky Hook proves to be a formidable tool. It has the ability to effortlessly handle heavy loads which are commonly associated with hazardous lifting injuries, thereby setting new standards in safety measures. This humble tool makes light work of seemingly hefty tasks, proving that size isn’t always directly proportional to effectiveness.

Every workplace, whether it’s a bustling shop or a rugged job site, frequently encounters the issue of lifting materials, parts, and tooling that fall well outside the safe lifting capacity of an operator. Addressing this issue has seen the emergence of an entire industry, which, while providing multiple solutions, often overlooks niche requirements in material handling applications.

A primary area that seems to have been dismissed too quickly is the operator’s need to lift loads that surpass their personal lifting capacity. This often falls into a grey area, somewhere between what an individual can manage and the extreme capacity of a multi-ton overhead or jib crane. The Sky Hook elegantly fills this gap, enabling the operator to carry out tasks such as moving a 150 lb. tooling from a storage shelf onto a CNC mill table without risking an injury.

Traditional lifting tools like overhead and jib cranes pose their own set of challenges. Their high costs, complex installation requirements, and mandatory certified personnel for operation often make them less than ideal for many settings. The Sky Hook addresses these concerns while providing the required lifting capacity for most day-to-day operations.

For half a century, Syclone ATTCO Service has committed itself to the creation of an enhanced lifting product, one that fits snugly into the demanding landscape of the ergonomic material handling industry. Their initial product, launched in 1969, was the Sky Hook. In the heart of the manual machine shop industry, this tool quickly garnered attention, becoming an essential choice for lathe and mill operators requiring a safe method to handle heavy chucks and tooling.

This family-run enterprise has witnessed an evolutionary journey. Over the past decades, Syclone ATTCO has consistently adapted and refined its product based on customer feedback and emerging needs. This relentless pursuit of excellence has resulted in an all-inclusive, application-driven lifting solution that effectively bridges the gap between operator limitations and large industrial lifting equipment.

The Sky Hook distinguishes itself by offering a superior lifting solution. Its defining features are its mobility, compactness, light weight, and independence from an external power source. Despite costing a fraction of its larger counterparts, it is perfect for executing simple, single-operator lifts of awkward, hard-to-reach loads up to 500 lbs.

The Sky Hook’s design is a marvel in itself. From its sturdy base to its versatile boom, every aspect is specifically crafted to enable the precision handling of loads within a wide range of 50-500 lbs. Even the lightest model, weighing just 26 lbs., can be easily relocated across a work site while retaining the capacity to lift loads equivalent to four to five people.

However, don’t let the Sky Hook’s small stature deceive you. It is a tool of surprising versatility, capable of handling a wide variety of lifting tasks. Recognizing the varied needs of different settings, Syclone ATTCO Service has developed an array of models. These include devices that bolt to the floor, mount to a table, navigate narrow aisles, slide under equipment, or feature counterweighted bases to reach over and into machine cabinets. The company has adopted a customer-focused approach, demonstrating a commitment to provide unique solutions for each of their clients. They have the ability to design and build custom models based on specific requirements, ensuring that every customer receives a lifting solution perfectly tailored to their needs.

Standing at the height of an average person, the Sky Hook is designed to operate right where the user is. This thoughtful feature significantly mitigates the risk of dangerous and costly back injuries. The Sky Hook not only prevents lifting-related injuries but also becomes a valuable asset in saving time and money. Mark Spencer, a satisfied client from the Spencer Corporation, testifies to this, exclaiming how the Sky Hook has exceeded expectations and become an indispensable tool in their daily operations.

The Sky Hook product line offers a breadth of choices to meet various application requirements. It is available in both Chain and Cable models, and you can opt for either our Premium LoadLock clutch brake system or the simpler Economy Friction Brake. Each of these models offer specific advantages to the user. Premium Models boast upgraded casters and our unique LoadLock clutch brake for easy operation. Economy Models, on the other hand, feature a friction brake mechanism for secure load holding, offering a cost-effective yet reliable option.

Manufactured entirely in the USA, the Sky Hook is an embodiment of quality, safety-focused design and a long-standing history of success. Over the past 50 years, it has proven its worth across nearly every industry. As a family-owned and operated company, Syclone ATTCO Service maintains a close relationship with their customers, working with them to provide solutions tailored to their exact needs.

The Sky Hook is a testament to the fact that revolutionary solutions often come in simple packages. Its user-friendly design, coupled with the outstanding support and customization offered by Syclone ATTCO Service, makes it an unparalleled solution in the realm of lifting devices. If you are in search of a versatile, reliable, and cost-effective lifting solution, your search ends with the Sky Hook. Get in touch with Syclone ATTCO Service today to secure your precision Sky Hook lifting solution!

The post Introducing the Sky Hook: Not a Jib, Not a Crane, but a New Class of Lifter appeared first on IndMacDig | Industrial Machinery Digest.

The Importance of Machine Guarding

Machine guarding is essential in environments where heavy machinery, high-speed equipment, and hazardous tools are used. According to the Occupational Safety and Health Administration (OSHA), machine-related injuries account for a substantial percentage of workplace accidents. Common incidents include entanglement, crushing, cutting, and even fatal injuries caused by moving parts.

Effective machine guarding mitigates these risks by providing a physical barrier between workers and hazardous components such as blades, gears, and belts. It also prevents debris and materials from being ejected during operation, protecting nearby personnel. Beyond physical safety, well-maintained guarding reduces liability and demonstrates a company’s commitment to employee welfare.

Types of Machine Guards

There are several types of machine guards, each tailored to specific applications and equipment:

• Fixed Guards: Permanent barriers that provide robust protection against moving parts. Commonly used on conveyors, gears, and cutting tools, these guards are simple, reliable, and cost-effective.
• Interlocked Guards: Equipped with sensors that shut down machinery when the guard is removed or tampered with. This ensures that workers cannot access hazardous areas during operation.
• Adjustable Guards: Flexible solutions designed for machines that require frequent adjustments. These guards can be repositioned to accommodate various tasks without compromising safety.
• Self-Adjusting Guards: Often found on woodworking equipment, these guards adjust automatically based on the size of the material being processed, maintaining a consistent barrier.

Machine Guarding Standards and Compliance

Compliance with safety standards is not optional; it’s a legal requirement. OSHA outlines specific regulations for machine guarding under standard 1910.212, which mandates that moving parts must be shielded to prevent injury. Additional guidelines from organizations such as the American National Standards Institute (ANSI) and the International Organization for Standardization (ISO) provide detailed specifications for guard design and implementation.

Failing to meet these standards can result in significant penalties and, more critically, endanger the lives of workers. Regular audits, inspections, and employee training are essential to ensure compliance and maintain a safe working environment.

Innovations in Machine Guarding

The evolution of technology has introduced innovative solutions in machine guarding, enhancing both functionality and usability. Modern guards now integrate advanced materials, ergonomic designs, and automation for improved efficiency and worker convenience.

• Smart Guarding Systems: Equipped with sensors and IoT capabilities, these systems monitor machinery in real time, providing alerts for potential hazards and maintenance needs.
• Transparent Guards: Made from durable, shatter-resistant materials like polycarbonate, these guards allow operators to visually monitor machine operations without compromising safety.
• Ergonomic Designs: Guards are increasingly designed with user comfort in mind, reducing physical strain during operation and maintenance.

Benefits Beyond Safety

While the primary purpose of machine guarding is to protect workers, its benefits extend far beyond safety. By minimizing accidents and downtime, guarding systems contribute to increased productivity and cost savings. Efficiently guarded machines experience less wear and tear, reducing maintenance needs and extending equipment lifespan.

Moreover, a strong safety record enhances a company’s reputation, attracting skilled workers and fostering trust among clients and stakeholders. Investing in high-quality guarding systems is not just a regulatory necessity; it’s a strategic business decision.

Implementing Effective Machine Guarding

Implementing an effective machine guarding program requires a comprehensive approach:

• Hazard Assessment: Identify potential hazards associated with machinery and prioritize areas requiring immediate attention.
• Guard Selection: Choose appropriate guarding solutions based on machine type, operational requirements, and worker interaction.
• Training and Awareness: Educate employees on the importance of machine guarding, proper usage, and reporting procedures for damaged or missing guards.
• Regular Maintenance: Inspect and maintain guards regularly to ensure they remain functional and compliant with safety standards.
• Continuous Improvement: Stay updated on technological advancements and regulatory changes to enhance your guarding systems over time.

Conclusion

Machine guarding is an indispensable element of workplace safety, protecting workers from harm while boosting operational efficiency. As industries continue to adopt advanced technologies, the integration of innovative guarding solutions ensures that safety standards evolve alongside progress. By prioritizing safety through effective machine guarding, businesses can create secure, productive environments where employees thrive.

The post Enhancing Workplace Safety Through Machine Guarding appeared first on IndMacDig | Industrial Machinery Digest.

Comprehensive Capabilities Tailored to Industry Challenges

Wauseon Machine’s array of services caters to the most complex manufacturing demands, enabling clients to achieve their goals with precision and efficiency. Among its advanced capabilities are Saw Cutting, Welding, Heat Treating and Tempering, Laser Etching, Rapid Prototyping, Reverse Engineering, and Carbinite applications, all backed by the company’s stringent quality control standards.

Advanced Machining and Fabrication Processes

At the heart of Wauseon Machine’s offerings lies its versatile machining capabilities, crafted to deliver exceptional results across a range of industries:

Saw Cutting Excellence:

Wauseon Machine’s in-house saw cutting capabilities provide precision and adaptability for a variety of manufacturing needs. Whether it’s production or bundle cuts, the company leverages premium raw materials and quick turnaround times to meet diverse project requirements.

Robust Welding Solutions:

With extensive MIG and TIG welding expertise, Wauseon Machine delivers superior structural integrity and customization for projects. For specialized welding needs, the company taps into its trusted network of partners, ensuring top-quality outcomes tailored to unique specifications.

Heat Treating and Tempering:

Precision is critical in metals, and Wauseon Machine’s heat treating and tempering services refine metal properties to meet exact application demands. Operating furnaces up to 2100°F, the company provides hardening, tempering, and annealing processes, enhancing product durability and performance.

Laser Etching with Precision:

Utilizing the Tykma Vereo Fiber Laser Marker, Wauseon Machine delivers detailed and aesthetically pleasing laser etching on flat and round surfaces. This service supports custom logos, detailed font styles, and even photographic enhancements, combining functionality with branding appeal.

Pioneering Innovation with Reverse Engineering and Rapid Prototyping

Wauseon Machine’s Reverse Engineering and Rapid Prototyping services provide invaluable solutions for customers aiming to refine or recreate parts with precision. By utilizing cutting-edge tools such as the FARO Arm and metrology lab technology, the company ensures unmatched accuracy in part design and development. This capability supports customers in resolving engineering challenges, testing fit and functionality, and minimizing manufacturing risks.

Enhancing Tool and Component Performance with Carbinite

Wauseon Machine’s Carbinite technology, a tungsten carbide applied through Electro Spark Deposition, provides enhanced friction, grip, and wear resistance for critical components. By extending the lifespan of tools such as collets and clamp blocks, this service delivers measurable cost savings and operational efficiencies for customers.

Quality Control and Assurance: A Commitment to Excellence

Wauseon Machine’s state-of-the-art quality control lab stands as a testament to its unwavering dedication to precision and reliability. Equipped with advanced tools such as the FaroArm CMM and coordinate measuring machines with vision capabilities, the lab performs 3D inspections, CAD comparisons, and dimensional analyses, ensuring every product meets or exceeds customer expectations.

From Concept to Completion: Your Manufacturing Partner

With its multi-plant operations in Ohio and South Carolina, Wauseon Machine exemplifies what it means to be a comprehensive manufacturing partner. By continuously expanding its service portfolio and investing in advanced technologies, the company empowers manufacturers to overcome complex challenges and deliver exceptional products.

Whether you’re looking to enhance your capabilities with rapid prototyping, refine part designs with reverse engineering, or maximize component performance with Carbinite treatments, Wauseon Machine has the tools, expertise, and commitment to make it happen.

The post Wauseon Machine – Delivering End-to-End Precision Machining and Fabrication Solutions appeared first on IndMacDig | Industrial Machinery Digest.

Simulation has traditionally been used across all stages of design, from early capital expenditure (capex) planning to production routing optimization. That’s still the case today, but simulation models have recently made their way into production planning processes. “We take a simulation model of our production environment and run the order forecast through a few scenarios to make better decisions around worker allocation, WIP [work in progress] strategies and quantities, and even planned downtime for equipment,” says Michael Sarvo, digital design business development manager for Rockwell Automation. “This is a winning strategy because you can improve your reaction time to constantly changing conditions.”

Simulation differentiates the early adopters from the laggards within various segments and industries, says Iiro Esko, industry manager and digital transformation architect for Siemens Digital Industries. “You use simulation through optimization, training, commissioning, acceptance testing, engineering, and in connection with procurement and sustainability planning,” he says.

The State of Simulation

While some top-level manufacturers understand the benefits that simulation software offers, not everybody is on board yet. “There’s a massive spectrum of adoption and tech level out there,” Sarvo says. “Some companies are all in and have made simulation and related practices an integral part of how they do business, while others still don’t see how this kind of technology could possibly be a benefit.”

There are many different types of simulation software, as well as different ways to classify it, notes Ravi Aglave, director for chemical and process industry at Siemens. Control simulation, for example, relates to how you can achieve control of any given process. Molecular-scale simulation illustrates how materials will behave at a molecular level. Structural simulation provides insights into how the structure of a building or a car or an airplane might behave or respond.

Simulation can be defined by its scale — anywhere from molecular to the whole plant — or by the depth of understanding it provides. Before considering simulation software, manufacturers first need to understand what they want to get out of it. Is it to optimize costs, quality, or system operation, or to increase profitability? Simulation in automation addresses all of the above: It reduces costs by minimizing trial and error in physical setups, enhances flexibility by allowing rapid adjustments to system designs, and improves product quality through refined control over manufacturing processes.

Sarvo explains the benefits simply: “Simulation tools provide a more efficient and more accurate means of predicting the future. When you have better and earlier predictions, you have more opportunity to plan, design, and execute, resulting in better outcomes.”

At Rockwell Automation’s Emulate3D User Group Meeting in October, integrator Automation Intelligence explained how it used simulation software to help the second largest distributor of beer, wine, and spirits understand whether it could add 20% new volume without constructing another building.

Republic National Distributing Company (RNDC) handles more than three million cases per year at its distribution center in Morgan Hill, California. But the company faced challenges due to labor shortages, growing demand, new material handling equipment, and resource allocation within a multilevel pick module. The strategy was to replace manual processes and storage areas with high-tech automation and control systems. But such significant upgrades bring their own risks.

“Think about it — you must shut down existing production, install new, unfamiliar systems, and train engineers, operators, and maintenance personnel,” Sarvo says. RNDC used Emulate3D to model its production environment to understand how the new automation could be used to meet production demands. “Because of the way Emulate3D software works, they were also able to test and debug their new control systems against the model before the real system was built, and they were able to train their people on the new processes and equipment, so they were ready for production as soon as the new system was online.”

In production, RNDC continues to use the hybrid simulation/digital twin models to run forecast data and optimize daily production schedules.

How the Digital Twin Fits In

At its core, simulation software creates digital twins of production systems, machines, and workflows, allowing manufacturers to explore a wide range of scenarios without the cost and risk of real-world experimentation.

For Siemens, a digital twin is the digital representation of theoretically all different types of simulation, says Andrea Sassetti, innovation manager, Siemens Digital Enterprise Lab at MxD. “We are able to cover many different aspects — molecular fluid dynamics, mechanic, kinematic — and also simulate a sensor and see how it performs in a digital space,” he explains. “All those types of things are possible using simulation tools that are capable of converting the simulated activity for the behavior of standard equipment or device or valve or motor in a digital point of view.”

In partnership with the U.S. Department of Defense, MxD in Chicago is an ecosystem designed to solve critical manufacturing challenges. There, the Siemens Digital Enterprise Lab provides a live mock manufacturing environment to demonstrate Industry 4.0 technologies with the merging of virtual and physical worlds.

At MxD, Siemens partnered with collaborative robot (cobot) manufacturer Universal Robots (UR) to create a palletizing cell, for example, to simulate the robot. “We are able to simulate all the behavior of the equipment — pick the parts, drop on the pallet, open and close the gripper, and do many cycles based on position,” Sassetti says. “All these types of things can be done before purchasing the hardware, including the metal, the PLC, and the end effector.”

The UR simulations are also concerned with safety, Sassetti adds. They can simulate what the cobot will do when next to a human operator and determine where in the process it’s necessary to slow down or even activate the emergency stop.

Hirata, a Japanese system manufacturer that supplies transmission and engine assembly lines and electric vehicle and other automotive production equipment to numerous manufacturers, uses Siemens’ Process Simulate as part of a broad digital transformation initiative. With it, the company has been able to shorten the time it takes to go from product design to manufacturing.

Previously, Hirata required three engineers working 3–10 days to complete equipment validation. Using Process Simulate for 3D model validation, Hirata has reduced workforce hours by 90% and human-hour requirements by 66%.

Hirata has also used digital simulation tools to teach its robots offline. “Previously, we had to turn on the power, start up the robots, and then perform the teaching work to check for interferences, cable twists, and other issues,” says Shoichiro Seki, general manager of the engineering departments at Hirata. “Now all of that can be performed offline, which is incredibly helpful for manufacturing.”

Offline Robot Programming

As a subsector of simulation software, offline robot programming (OLRP) can greatly benefit how integrators and manufacturers program, deploy, and reprogram their robots by eliminating the need to interrupt productivity.

Octopuz, which focuses specifically on the OLRP sector, says the software is just finding its footing in the general manufacturing market. As opposed to factory simulation software, which simulates how parts move through production, for example, and figures out bottlenecks, OLRP takes a much more focused view by creating production code that can be used in the real world.

The top application for Octopuz’ OLRP offering is robotic welding. “Rather than programming the robot by standing in front of it with a teach pendant to do all the things needed to do a weld, you’re going to use software like Octopuz to do all that programming in a virtual environment,” says James Schnarr, senior product manager at Octopuz. “[Users] can make sure that the program is free of errors — so the robot’s not going to have errors and there’s not going to be any collisions. And then we actually produce the robot code at the end of it. They bring it to their robot, and it’s ready to run exactly as they expected it to based on what they designed in our software.”

A key benefit to using OLRP as opposed to a teach pendant is to eliminate robot downtime. Typically, a user programs a robot to do one task. If the job changes, the time it takes to program the robot for a new task or product is time that the robot is not working.

That’s in part why robotic welding is a particularly important OLRP application. In robotic welding, changing one part can mean reprogramming 100 different welds. “If I’m standing in front of the robot with the teach pendant, I’m doing two things: I’m taking a long time to program those 100 welds, as I manually jog the robot through each of those welds and do the programming, but I’m also taking the robot off production,” Schnarr says. “That might take a day, it might take five days, it might take three weeks, depending on the complexity of the welds and of the programming. And if my robot’s getting programmed, then it’s not running production.”

Conversely, with OLRP, the robot can be performing its initial weld job while the software is running on the computer. When the manufacturer is ready for the robot to move to the next job, the code is ready as well. “I might do some touch-ups, but I’m going to be ready to go with production in a few hours, maybe a day, as opposed to multiple days or weeks,” Schnarr says.

Aside from welding, applications that benefit from simulation software are other high-mix, low-volume operations, such as a fab shop performing contract work for several different customers.

Jomar Machining & Fabricating in Middlebury, Indiana, manufactures tire shredding equipment used for recycling tires. The company employs robots for hardfacing — the type of welds that most humans don’t like to do, says Lyndon Schlabach, robot programmer for Jomar, who also oversees the company’s welding operations.

“We had one robot that I was programming before we bought Octopuz. We were stopping the robot for a week straight just to do programming on a part,” Schlabach says. “With Octopuz, we can program the robots while they’re in production.”

Jomar has also found that the robots programmed offline produce better-quality welds. “On a surface weld, like we’re doing, to try to manually program all these paths and make them so they line up correctly to get a good even weld, it took a lot of time,” Schlabach says, adding that parts made by the Octopuz-programmed robots last longer in the field.

Artificial Intelligence and the Industrial Metaverse

Simulation continues to evolve. “Today, the kind of simulation that you can run is probably a trillion times what you could do maybe 10 or 15 or 20 years ago,” Aglave says. “There are two parallel advances that are happening. One is the computing power itself, and the other is the understanding of the behavior of objects and systems — the physics behind it.”

As with many other manufacturing technologies, artificial intelligence (AI) is likely to speed the progress of simulation capabilities. “It only makes sense that we’ll see artificial intelligence integrations of all kinds,” Sarvo says. “People are certainly using AI decision-making algorithms. There are APIs [application programming interfaces] for that sort of thing, and powerful simulation tools provide open scripting environments where users can extend the software’s functionality as they like.”

AI is also gaining momentum to create simulations that are a hybrid between physics- and data-based models. “The second thing that will be gaining momentum would essentially be how to take a large simulation and reduce it down into a simpler behavioral model for controlling the manufacturing operations,” Aglave says, referring to this as an executable digital twin. “The simulation essentially acts as a distilled, intelligent brain that can be used to ask questions and immediately get answers to make changes to the manufacturing operations.”

Combining AI with digital twins creates an industrial metaverse. “The next level of the digital twin is the industrial metaverse because it’s a place where we are leveraging the real data in combination with the digital twin, as well as the AI that is running behind the scenes in order to validate what is happening in the plant,” Sassetti explains. “It’s a live environment where you are able to test new possible solution improvements.”

By: Aaron Hand, TECH B2B, A3 Contributing Editor

The post How Simulation Software Powers Real-World Efficiency appeared first on IndMacDig | Industrial Machinery Digest.

Regular preventive maintenance (PM) on forging equipment offers additional benefits. Ensuring the machinery operates without unforeseen failures or malfunctions reduces maintenance needs and lowers repair costs. Furthermore, it decreases the likelihood of producing defective or substandard products. Safety is also improved by minimizing potential hazards and reducing the risk of injuries.

Although many forgers follow routine maintenance guidelines, most continue production until the equipment breaks down. Given the longevity of certain forging machines in operation since the 1950s and 60s, technicians may lack the knowledge required to troubleshoot problems or recognize worn or failing components, which increases the risk of a major breakdown. Studies have shown that the cost of unplanned maintenance can be three times higher than planned maintenance.

“The purpose of a systematic preventative maintenance program is to identify and address potential issues before they escalate. PM is designed to optimize machine reliability and performance while saving costs over time by avoiding serious breakdowns,” says Bill Goodwin, Vice President of Sales and Engineering Ajax/CECO/Erie Press (ACE), the largest forging equipment supplier in North America.

Traditionally, PM is performed by facility personnel who conduct routine inspections, maintenance, and repairs on assets to ensure that they are functioning properly. However, a growing number of forgers are discovering the value of partnering with equipment OEMs for customizable PM programs that incorporate the industry’s best proactive maintenance practices.

“In essence, the OEM becomes an extension of the forger’s maintenance team through best practice PM, proactive training, and even spare parts programs. The goal is to customize the program to fit within the budget and provide as much, or as little, support as needed,” says Goodwin. ACE, with 145 years of experience in equipment manufacturing and more than 300 years of combined forging knowledge, is the longest-running, most experienced forging company in the world. The OEM provides a comprehensive array of forging equipment including upsetters, presses, programmable hammers, forging rolls, and automation solutions for various forging materials such as carbon steels, aluminum, titanium, and super alloys.

The Importance of Forging Equipment PM

Today, ACE is offering the most comprehensive preventative maintenance program in the forming and forging industry. The customized program not only includes training activities and scheduled replacement of consumables, but also develops repeatable maintenance tasks and follows PM best practices for forging and forming equipment.

In this program, the OEM first conducts a preliminary review of any existing PM program documentation of what is currently performed. This includes the life cycle of frequently replaced parts.

Next, the OEM conducts a “health check” to determine the equipment’s current condition, running clearance, electrical system, and pump performance. Based on the results of the health check, the OEM recommends corrective actions to restore the equipment to its original specifications.

ACE is in a unique position to utilize the full documentation of equipment in its broad portfolio of brands, along with extensive maintenance and repair experience accumulated over many decades. With its core brands founded in the 1800s, the company offers a full line of products, including standard mechanical forging presses, upset forging machines, forging rolls, hydraulic forging, forming, compression molding, cold extrusion, compaction, and roll ring preform presses along with stretch forming and straightening machines, solid die forgers, trim presses, programmable die forgers, and custom-engineered hydraulic presses.

In the next step, a customized preventive maintenance program is created. This can vary, but typically involves following best practices for lubrication; daily visual inspections for signs of wear, leaks, or damage; listening for abnormal vibrations/noises when equipment is running that can indicate underlying issues; monitoring the presence of dirt or other foreign particles that can deteriorate the machinery’s efficiency; regular calibration to avoid misalignment or imbalanced equipment; and documenting all checks, observations, and maintenance tasks performed.

Goodwin stresses that the extent of the PM program is based on factors such as the type of equipment, production, onsite support, and desired PM intervals. “It can be scaled up or down to take into account the maintenance team’s experience, availability, and turnover,” he says.

Although PM is typically performed on-site, some actions can be completed remotely. ACE utilizes advanced collaboration tools and real-time video communications to connect with technicians so each can see, discuss, annotate, and resolve many situations at hand.

Spare Parts Programs to Minimize Downtime

Ensuring smooth operations goes beyond just the maintenance of forging equipment. It also entails having essential spare parts available at a moment’s notice to minimize production downtime.

Consequently, the PM program can also include a separate spare parts stocking program that anticipates expected maintenance requirements. By utilizing measurable production rates, ACE can proactively schedule service and replacement of critical parts through an online portal. Potential critical failures can be identified and addressed before occurring.

To ensure the highest production uptime of forging equipment and prevent lengthy unexpected downtime, the stocking program typically not only includes consumables but also essential parts that can traditionally have very long lead times.

“Common consumables include friction plates and driving plates for presses and upsetters, or piston heads, rods, rings, and packings for hammers. However, it is even more important to stock main gears, eccentric shafts, and rams to avoid long lead times for replacement,” says Goodwin.

According to Goodwin, with the parts stocking program the forger only pays a percentage of the cost up front and the balance when they take possession of the part – up to 2 years later. With minimal up-front investment, the custom stocking program can eliminate many months of downtime waiting on long lead time parts. Express shipping costs are also eliminated since parts are readily available.

Even though the high impact nature of forging will eventually take its toll, with proper PM the equipment can be kept productive for many decades, and potentially for the better part of a century.

“Ensuring proper PM is not merely a task, but an investment in the longevity of your forging equipment, the quality of your products, and the productivity and safety of your workforce. By implementing a proactive PM program, manufacturers can position themselves to reap the maximum benefits from their equipment for decades to come,” concludes Goodwin.

The post Forging Greater Productivity with Next Gen PM appeared first on IndMacDig | Industrial Machinery Digest.

The manufacturing economies of the G7 group of nations face growing competition from the rest of the world, as globalization connects countries’ economic fortunes more closely. Huge changes have taken place within manufacturing as companies – particularly within the industrialized nations – turn to automation to tackle growing problems with skills and labor shortages and rising input costs, coupled with demand for greater efficiency and throughput. In addition, world events resonate within industry and the impact of global conflicts on energy costs and supply chains are affecting production.

Meanwhile, many of the BRICS nations have improved production capacity and output growth, as domestic demand increases. In the current climate, opportunities may exist for the BRICS economies to capitalize on weaker projected growth for the G7 nations and expand their manufacturing industries due to costlier exports and already strong production capacity. This begs the question, can the BRICS nations take advantage of the current slump in manufacturing output in the G7, and will they choose to do so?

In existence since 1973, the G7 is a political and economic forum of industrialized nations (Canada, France, Germany, Italy, Japan, the United Kingdom, and the United States, with the European Union as a non-enumerated member). Formed much more recently, the BRICS geopolitical bloc comprises Brazil, Russia, India, China, South Africa, Iran, Egypt, Ethiopia, and the United Arab Emirates. As a whole, the BRICS nations have traditionally had lower production capacity than the G7 countries.

According to the latest data from Interact Analysis’ quarterly Manufacturing Output Tracker (MIO), 2024 will prove tough for manufacturing worldwide. Despite lower output being forecast for most nations, the dip for many will be relatively low. When China is excluded from the global data, production output is expected to drop to -0.9%. China, the ‘Factory of the World’ continues to prop up the figures, with the forecast at 0.6% when it is included in the data.

Manufacturing conditions remain difficult for the G7

Germany’s manufacturing industry has been the worst hit of the G7 nations as it attempts to shift its reliance on Russian gas, experiences falling business from China, and is undercut by cheaper production elsewhere. The overly bureaucratic industrial and political system continues to hamper recovery. Taking the German car industry as an example, Volkswagen recently announced plans to close two of its production facilities in its home country. And it is not the only major automotive company to do so, with others considering plant closures, including tyre giants Continental and Michelin. Ford has revealed it is cutting 3,500 jobs at a German plant, and Automotive Cells Company (ACC) has halted construction on battery manufacturing sites in both Germany and Italy.

Italy has seen minor effects of the global slowdown, but the severe problems in Germany have not manifested as acutely as feared, with machinery sales remaining robust. However, growth has flatlined and the current situation is wait and see. High production costs and production capacity in many large European economies mean they have struggled to increase production. Both Germany and Italy have witnessed companies moving factories to cheaper neighboring countries like Romania, Czechia, Hungary and Poland. The effect of this movement within the European Union benefits the wider G7 to some degree, but is to the detriment of individual G7 members.

We have yet to see any impact of France hosting the 2024 Olympic Games show within the manufacturing data, so it is unclear what effect, if any, the event will have on the nation’s economic fortune. Meanwhile, the UK continues to feel the aftershocks of Brexit, with import and export costs increasing. As the economy falters, it remains unclear whether a change of government will bring about changes in relations with the rest of Europe and policies that affect manufacturing.

Japan is the third largest manufacturing economy in the world, but it continues to struggle as the accelerating decline of the yen places households under pressure. As a net importer, the pressure on internal consumption is coupled with emerging southeast Asian economies undercutting it in some of its key manufacturing sectors.

Within the G7, the US is not experiencing economic pressures to the same extent and consumer demand has remained robust, despite rising prices. The Interact Analysis MIO Tracker is not currently forecasting a contraction for US output in 2024. Additionally, US industry has benefitted from government policies such as the CHIPS and Science Act. The US has invested heavily into the growing semiconductor industry to secure domestic production and reduce imports from China. This stimulus will likely continue to boost manufacturing in the US. With less proactive measures from the government, Canada’s manufacturing data is weaker, affected by a dip in global demand for metals. The latest drop has increased calls for action to boost production.

What does this mean for the BRICS economies?

With the current downturn largely affecting the Americas and Europe in particular, the BRICS economies have shown greater resilience. Despite China’s weak recovery in domestic demand, due to its fluctuating housing market, it is still expected to increase production output by +2.3% in 2024 as exports rebound. So far, the government has avoided large-scale economic stimuli, although reports now suggest that some form of stimulus is being planned. The real estate market is expected to stabilize in 2025, while higher rates of growth are predicted for production output into 2026 and 2027.

India has been particularly resilient and is on a strong growth path. Its high population density and poor availability of raw materials mean it is unlikely to become the ‘next China’. However, Interact Analysis has raised India’s long term growth forecast to +5.4%. India is capitalizing on weaknesses in the G7 through its manufacturing industry as it continues to trade widely with, for example, China, Russia and the US. A significant increase in investment is also being hailed as a key driver of growth. S&P Global has predicted it could rise to become the third largest economy in the world by 2030. It may well be that the Indian government’s ‘Make in India’ flagship program is starting to bear fruit. However, it is notable that India’s manufacturing industry is facing some challenges within certain sectors from smaller countries, particularly in areas such as semiconductor manufacturing from territories such as South Korea and Malaysia.

The overall picture is inconsistent across the manufacturing industries of all the BRICS nations. For example, according to the MIO, the Covid-19 pandemic affected Brazil more than any other large manufacturing economy and it is still regaining lost ground following a particularly difficult 2023. Brazil is not expected to see manufacturing growth return until at least 2025 and it remains heavily reliant on exports to China and the US, both of which have dipped. However, it is anticipated that monetary policy changes will return its economy to growth and boost manufacturing.

Russia’s economy has generally held up, despite the war in Ukraine, and it has spent heavily on military production. But it is not clear how long this will last. Additionally, some of the smaller BRICS economies, such as Ethiopia, South Africa and Egypt, have experienced a range of political and economic challenges that have affected manufacturing productivity. The UAE in contrast has seen diversification policies and increases in oil prices and production boost its output and economy.

So, can and will the BRICS economies capitalize on the current G7 manufacturing slump?

Any capital BRICS nations are going to make from the current downturn will need to be swift, as another manufacturing downturn is not forecast by Interact Analysis until 2029 or 2030. Looking at the MIO Tracker, the Americas is forecast to see a compound annual growth rate (CAGR) of 5.4% between 2024 and 2029, considerably higher than the 3.9% anticipated for Europe and Asia. Asia’s lower 5-year CAGR is mostly due to the sheer size of China’s manufacturing industry, as it is harder to achieve growth from a larger base. India’s manufacturing CAGR for the 5-year period is 6% and Asia as whole – excluding China – is 5.5%.

Growth trajectories are predicted for the 3 major manufacturing regions

There is little time for the BRICS nations to capitalize on the widespread manufacturing struggles of many of the G7, so it is unlikely that much additional growth will be generated in the short term. The post-Covid nearshoring trend is continuing and government incentives to generate domestic investment (such as the CHIPS Act in the US and Make in India) may become more widespread. With the G7 undoubtedly facing increasing competition from the rest of the world, this may be a means by which wealthier countries attempt to protect their manufacturing industries and reduce over-reliance on Chinese imports. However, China is such a dominant force in global manufacturing, with all the benefits that rich natural resources and domestic consumption bring, that it is unlikely to see any significant impact in the near term.

The picture is also far more complicated than simply G7 vs BRICS nations. We have seen smaller, more agile nations such as Indonesia, Malaysia, Czechia and Poland grow their manufacturing industries and specialized industries as larger territories experience output struggles. With such a wide range of variables in place and an imminent global recovery forecast, it appears that the BRICS nations are unlikely to make manufacturing capital out of the current downturn in many of the G7 economies.

By Jack Loughney, Senior Research Analyst – Interact Analysis

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A Legacy of Excellence: Meet Rick Arcaro

With 27 years at HYDMECH and nearly four decades in the industry, Rick embodies the company’s dedication and expertise. “I’ve been with the company since 1986, and it’s only the third job I’ve ever had. It’s a great industry—addictive, really. You get to see new stuff every single day; you’re never stale,” he shared enthusiastically.

Rick’s long tenure at HYDMECH underscores the company’s stable and nurturing work environment. “Working for HYDMECH is fantastic because we’re not a stale company. We’re very progressive, innovative, and just a great place to work. We have a lot of good people,” he added, highlighting the company’s strong internal culture and commitment to employee satisfaction.

What Sets HYDMECH Apart?

When asked about what distinguishes HYDMECH’s products from competitors, Rick provided a comprehensive overview. “Our machines are bar none the easiest to run in the industry,” he stated confidently. This ease of operation is a significant differentiator in a market where labor shortages and the need for efficient training are pressing concerns.

One of HYDMECH’s standout features is their user-friendly interface. “We’re the only machine tool builder that actually gives you a directions door chart in our PLC on our machine, how to run it. So if your operator’s not there today, somebody can come over and be a saw operator and keep your production going.” This level of accessibility ensures that even less experienced operators can manage the machinery effectively, minimizing downtime and maintaining productivity.

Rick also emphasized the practicality of HYDMECH machines in terms of maintenance and part replacement. “Our machines are built with a lot of common components. Anything on a saw that we don’t machine, weld or fab, you can buy at a local supply house. So supply chain issues, replacement parts are very simplistic on HYDMECH machines.” This approach not only reduces operational costs but also enhances the reliability and longevity of their equipment.

Driving Innovation in a Changing Market

Innovation remains at the core of HYDMECH’s strategy. “Keeping up with the market, one thing coming out of COVID taught a lot of people, how to deal with supply chain, but more so how to deal with labor and I believe more the lack of labor,” Rick explained. The pandemic highlighted the vulnerabilities in global supply chains and exacerbated the existing labor shortages, prompting companies like HYDMECH to adapt and innovate.

To address these challenges, HYDMECH focuses on making their machines as easy and simple to operate as possible. “Our machines have to be easy, simple, and non-intimidating to run. So that basically, again, distinguishes us from some of the other competitors” Rick noted. This user-centric design philosophy ensures that businesses can maintain high production levels even with a limited pool of skilled labor.

Rick highlighted several key innovations in HYDMECH’s new product line. “The innovations we have are easier to operate than they were 10 years ago, 15 years ago. Our production levels are higher. A lot of that’s due to components on machines. In fairness to our market, a lot of it’s due to the blades. We build the machine, we don’t build the blades. The innovation of blades have come a long way in the last 10 years as well.”

Furthermore, HYDMECH is expanding its reach into automation. “We sell automation daily. The sawing market has now held a bit of a different standard. 10, 12 years ago, “a saw is a saw”. Now they’re referred to as machine tools. And it’s a big difference. And you’ve got people buying high-end sheer press brakes and lasers, and now our machines are going next to them.” This shift signifies HYDMECH’s commitment to integrating advanced technologies that align with the evolving demands of modern manufacturing.

Targeting a Diverse Market

HYDMECH’s versatility is a key strength, allowing them to cater to a broad spectrum of industries. “HYDMECH for a lot of years has always been a leader in fabrication. A lot of our machines have the capability to miter cut angles, shapes, products. That’s where the business started. The owner of the company was the innovator of the first bandsaw machine where the head moved instead of the material,” Rick recounted.

The company’s flagship machine, the S-20, stands as a testament to their innovative spirit. “If you go out and Google an S-20, it’s the highly most recognized machine name and brand in the world. It’s the most copied machine name and brand in the world. So that’s got to be some sort of flattery. We must be doing something right.”

Over the years, HYDMECH has expanded its capabilities beyond fabrication to compete in the chip market. “We’ve developed a much better standard of just straight cutting for the chip industry. Where we hung our hat in fabrication, we’ve certainly now compete daily in the chip market. So we’ve become a very large Swiss Army knife type company that we can walk into the small two-person machine shop to the service centers of automotive plants, forgers that may be employing 300 people. We fit all market segments,” Rick elaborated.

This adaptability ensures that HYDMECH can serve a wide range of clients, from small businesses to large industrial operations, providing tailored solutions that meet their specific needs.

Commitment to Quality and Sustainability

HYDMECH’s commitment to quality is evident in every aspect of their operations. “Quality is at the core of HYDMECH’s operations. We adhere to stringent quality control processes and hold various certifications, including ISO 9001 and ISO 14001,” Rick emphasized.

Moreover, HYDMECH is dedicated to sustainable practices and corporate social responsibility. “We implement eco-friendly manufacturing processes, minimize waste, and strive to reduce our carbon footprint. Additionally, HYDMECH engages in community initiatives and supports various social causes, reinforcing our role as a responsible corporate citizen,” Rick highlighted.

This holistic approach not only enhances the company’s reputation but also aligns with the growing emphasis on sustainability within the manufacturing sector.

Global Reach and Exceptional Customer Support

With a global footprint, HYDMECH ensures that its products are accessible to customers worldwide. “We serve customers across different continents, ensuring that our products are accessible wherever needed,” Rick stated. “We pride ourselves on providing excellent customer support, offering technical assistance, maintenance services, and training to ensure optimal performance of our products in the field,” Rick added.

This comprehensive support system ensures that customers can maximize the efficiency and longevity of their HYDMECH machinery, fostering long-term partnerships and customer loyalty.

Promotions and Future Outlook

As FABTECH 2024 closed, HYDMECH is keen on maintaining its momentum. “HYDMECH’s offering a package on our machines. From now until mid-December, we’re offering a 7% discount on several of our machines and accessories and packages. So we’re looking to keep our backlog moving,” Rick announced.

However, the company is experiencing high demand, with bookings already filling into early 2025. “One challenge for us is we’re already booking into 2025 Q1, unfortunately some Q2. We’ve had a very good year and I’m certainly not going to apologize for that for lead times, but it’s a challenge. I still got to give somebody an incentive to wait for a HYDMECH because there are other choices out there. So I believe we’re worth the wait,” Rick assured.

This robust demand reflects HYDMECH’s strong market position and the trust that customers place in their products. The company’s ability to consistently deliver high-quality, reliable machinery ensures that it remains a preferred choice in a competitive landscape.

Looking Ahead

As the manufacturing landscape continues to evolve, HYDMECH remains poised to lead with innovation and adaptability. Rick Arcaro’s insights at FABTECH 2024 revealed a company that not only honors its rich legacy but also embraces the future with cutting-edge technology and a customer-centric approach.

“HYDMECH is a unique company in that area,” Rick concluded. “We strive to reduce material handling, optimize processing, and give operators the tools they need to run multiple machines efficiently. This focus on innovation and efficiency sets us apart and ensures that we continue to meet the diverse needs of our customers.”

With its unwavering commitment to quality, innovation, and customer satisfaction, HYDMECH is well-positioned to navigate the challenges of the modern manufacturing industry and continue its trajectory of success.

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Why OSHA Inspections Matter

OSHA is dedicated to maintaining safe workplaces, and inspections play a vital role in enforcing this mission. Companies in high-risk industries, those with recent complaints, or workplaces where severe injuries have occurred are among those most likely to face an OSHA inspection. Beyond the immediate implications of an inspection, keeping workplaces in compliance with OSHA standards significantly reduces the likelihood of injuries, improves morale, and even enhances productivity.

Preparation Is Key: Laying the Groundwork for a Successful Inspection

Review and Organize Documentation A well-maintained record of safety documentation is the foundation of a strong inspection process. OSHA mandates that employers keep accurate records of workplace injuries and illnesses, including OSHA 300, 301, and 300A forms. Ensuring these documents are current, accurate, and easily accessible demonstrates a commitment to compliance and can make a positive impression on inspectors.

Ensure Training Compliance Safety training, especially on OSHA-regulated topics like hazard communication and personal protective equipment (PPE), is essential. Keep a log of training records that includes dates, employee names, and the content covered. OSHA inspectors will assess these records to verify that training is thorough and frequent enough to mitigate known risks effectively.

Conduct Routine Safety Audits Regular safety audits offer insights into potential hazards and ensure that corrective measures are taken before they escalate. Forming a safety committee or assigning a safety officer to oversee these audits can foster a culture of proactive safety management. Documenting these audits and their findings is equally important, as OSHA inspectors may review these records as part of their evaluation.

Prepare for the Inspection with Mock Walkthroughs Conducting a mock OSHA inspection can identify areas for improvement and highlight any gaps in safety practices. This exercise not only ensures compliance but also familiarizes team members with the inspection process, minimizing stress when an actual inspection occurs.

Understanding the Inspection Process

When an OSHA Compliance Safety and Health Officer (CSHO) arrives for an inspection, they will typically begin with an Opening Conference. In this phase, the CSHO explains the purpose of the visit, which may be scheduled or unannounced, depending on the circumstances. For instance, inspections related to severe incidents or imminent dangers are often unscheduled to capture real-time practices.

Request Identification and Verify the Scope of the Inspection Politely ask the CSHO for identification and ensure their credentials are in order. Once identification is confirmed, clarify the inspection scope, as some inspections may focus on specific hazards, while others may be comprehensive. Designating a company representative to handle communications with the inspector helps maintain organization and control over the inspection process.

Define Internal Roles and Responsibilities Assigning specific roles—such as a point person to accompany the inspector and a record-keeper to document the inspection process—helps ensure that key aspects of the inspection are handled promptly and accurately.

The Walkaround: Ensuring Compliance in Real Time

During the Walkaround Inspection, the CSHO will tour the facility, inspecting specific areas, equipment, and work practices. This stage is critical, as it provides the most direct insight into OSHA’s evaluation of your workplace.

Document the Inspector’s Movements and Observations During the walkaround, your designated company representative should take detailed notes on every area inspected, equipment observed, and any specific safety practices noted by the inspector. Photos can also be valuable for your records, particularly if the inspector highlights areas of concern.

Display Normal Working Conditions Ensure that work operations during the inspection reflect typical conditions rather than adjusting or halting activities. This approach demonstrates transparency and adherence to safety standards as they are practiced day-to-day, which can work to your advantage.

Limit Access to Confidential Areas OSHA allows employers to mark certain areas as confidential if they contain sensitive information or trade secrets. Discuss these designations in advance and inform the inspector of any restrictions, while still accommodating the needs of the inspection.

Handle Employee and Management Interviews with Care Inspectors often interview employees during the inspection process. To facilitate these interviews:

• Educate Employees on Their Rights: Inform employees that they have the right to request a representative, refuse recording, and answer questions without speculation. These interviews offer employees a chance to share their experiences openly, and educating them about the process beforehand can promote a constructive atmosphere.
• Debrief After Interviews: After the interviews, consider holding a brief meeting with employees to review topics discussed, which helps maintain alignment across safety practices.

Addressing Findings in the Closing Conference

Following the walkaround, the inspection concludes with a Closing Conference. During this phase, the CSHO will discuss any preliminary findings, answer questions, and clarify possible violations.

Seek Clarification on Any Observations or Citations It’s essential to ask questions and fully understand any citations, associated standards, and the nature of identified issues. Taking detailed notes during the conference will be valuable if further action is required.

Request Additional Time for Follow-Up If the inspector requires additional documentation or corrective actions, confirm a timeline for follow-up. This request provides a clear path for remedying concerns and completing outstanding requirements.

Post-Inspection: Follow-Up and Record-Keeping

Once an inspection concludes and any citations have been issued, OSHA requires employers to post citations in a visible area within the workplace for at least three days or until the cited issue is corrected. This posting period offers transparency and helps reinforce accountability.

Establish a Corrective Action Plan For citations that require action, creating a corrective plan with clear timelines, assigned responsibilities, and specific steps can ensure timely completion. Document every step taken to remedy each issue, as this information may be reviewed in future inspections.

Document All Follow-Up Actions Each action taken should be documented and stored for future reference. A comprehensive record not only aids in verifying compliance for future inspections but also supports continuous improvement in safety practices.

Maintain an Ongoing Compliance Program Implementing an ongoing compliance program ensures long-term adherence to OSHA standards. Regularly reviewing safety protocols, updating training programs, and conducting frequent audits are key to maintaining a safe work environment. For companies facing recurrent inspections or those in high-risk industries, such measures can significantly reduce the likelihood of future citations.

Leveraging Technology for Compliance Management

Digital tools can streamline OSHA compliance by centralizing safety documentation, tracking audits, and simplifying incident reporting. Companies like VelocityEHS offer solutions that help automate many compliance-related tasks, enabling efficient management of safety protocols and providing real-time data insights. Solutions like VelocityEHS not only support compliance but also empower employers to proactively address safety issues before they result in incidents or penalties.

In Summary

Successfully navigating an OSHA inspection comes down to thorough preparation, clear communication, and responsive follow-up. By maintaining up-to-date documentation, conducting regular audits, and fostering a culture of safety, organizations can minimize disruptions from inspections and focus on long-term improvement. Every step taken toward compliance is also a step toward a safer, more efficient, and productive workplace.

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The Evolution of Machine Vision

Historically, machine vision systems were built for controlled environments where consistent lighting and predictable object placement were crucial. As manufacturing environments evolved, these systems struggled to keep up with more complex requirements. AI has reshaped this landscape by allowing machine vision to analyze and interpret nuanced visual data, detecting subtle patterns and defects with remarkable accuracy. Today, machine vision AI systems are capable of learning from vast datasets, adapting in real time, and continuously improving their performance.

One of the most significant advancements is the shift toward edge computing, where data processing happens directly on the production floor rather than in a centralized data center. This setup reduces latency, enabling real-time decision-making for applications like quality control, defect detection, assembly verification, and packaging.

Key Components of Effective Edge Hardware

Implementing a successful AI-based machine vision system requires the right combination of software and hardware. Selecting the appropriate edge hardware is critical, as it serves as the backbone for running AI models and processing large volumes of visual data at high speeds. Here are some key hardware requirements for effective machine vision integration:

• Compute Power and Memory: AI models used in machine vision are data-intensive and require substantial computing power. Hardware equipped with modern CPUs and GPUs, as well as high-bandwidth memory, is essential to support these demands.
• I/O Support: Machine vision systems typically require connections to various cameras and networked devices. Edge hardware should support diverse interfaces to facilitate seamless integration.
• Environmental Protection: Industrial environments can be harsh, with exposure to dust, moisture, and temperature fluctuations. The selected hardware should be rugged enough to withstand these conditions.
• Expansion and Customization: As machine vision applications evolve, the ability to expand and customize hardware becomes increasingly important. Flexible hardware solutions enable manufacturers to scale their machine vision capabilities without extensive reconfiguration.

Scaling Machine Vision with Axiomtek’s IPC962A

One example of cutting-edge edge hardware designed for AI-enhanced machine vision is Axiomtek’s IPC962A, an industrial-grade computer that embodies the necessary robustness, power, and flexibility for these applications. Engineered with the specific requirements of AI in mind, the IPC962A provides manufacturers with a scalable and adaptable solution. Key features of the IPC962A include:

• High-Performance CPUs and GPUs: The IPC962A is equipped with advanced processors capable of handling complex AI algorithms, facilitating fast and accurate image processing.
• Comprehensive Connectivity Options: With multiple I/O ports, this system easily connects to various types of cameras and other devices, supporting extensive machine vision configurations.
• Multiple Display Capabilities: For high-resolution machine vision applications, the IPC962A supports multiple display outputs, allowing operators to monitor and control processes in real-time.
• PoE (Power over Ethernet) Management: The device supports PoE, enabling the connection of cameras and sensors that rely on power through Ethernet cables, simplifying setup and reducing the need for additional wiring.

The IPC962A’s versatility makes it ideal for a wide range of machine vision applications, from defect inspection in high-speed assembly lines to the verification of assembled components. With this solution, manufacturers can leverage the power of AI to achieve a higher level of quality control and operational efficiency.

The Benefits of AI-Driven Machine Vision

By integrating AI at the edge, machine vision systems become highly efficient tools for quality assurance, capable of delivering unprecedented accuracy and speed. The benefits are wide-reaching:

• Enhanced Accuracy: AI-driven machine vision detects minute defects that traditional methods might miss, ensuring consistently high-quality output.
• Reduced Downtime: Real-time processing at the edge allows for instant feedback, reducing downtime by identifying issues before they escalate.
• Improved Traceability: With advanced data collection and analysis capabilities, machine vision systems enable comprehensive tracking and traceability of products, aiding in quality assurance and regulatory compliance.
• Scalability: Edge-based AI systems can grow with the organization, adapting to new products, workflows, and market demands.

Axiomtek: Partnering for Future-Ready Solutions

Axiomtek’s machine vision solutions are designed to meet the challenges of modern manufacturing, supporting Industry 4.0 and smart manufacturing initiatives. With the IPC962A and other offerings, Axiomtek provides a comprehensive solution for manufacturers looking to embrace AI at the edge. Their commitment to customization and customer support ensures that manufacturers can effectively integrate these advanced systems, enabling them to optimize processes and improve productivity across the board.

By combining AI-driven machine vision with powerful edge hardware, Axiomtek is helping manufacturers realize the full potential of Industry 4.0, paving the way for a new era of precision, efficiency, and adaptability in industrial automation.

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Specifically, combining lasers and advanced robotics within enclosed workcells enables operators to efficiently and repeatedly clean components of different sizes, shapes, and materials on a level previously unattainable through manual methods.

“Automated laser cleaning systems are designed to cost-effectively clean high volumes of even the largest format parts and equipment and can be tailored to suit the size and complexity of the parts, while eliminating concerns over operator safety,” says Wayne Tupuola, CEO, Orlando, Florida-based Laser Photonics (NASDAQ: LASE), a leading global industrial developer of laser systems for cleaning and other material processing applications.

Industrial manufacturers frequently need to remove corrosion, grease, residue, and old coatings, or roughen the surface of metals prior to coating components and equipment. At times, contaminants or toxic substances need to be eliminated before further processing.

The challenge is that conventional methods like sandblasting, dry ice blasting, and chemical stripping are messy, time and labor intensive including preparation and cleanup, and require costly consumables. These methods can also pose risks to applicators and the environment so are scrutinized by regulators like OSHA and EPA.

As a much more efficient alternative, a laser cleaning robotic workcell usually consists of at least one laser-wielding robot, controllers, and safety equipment in a custom, see-through enclosure. These collaborative robots, or cobots, excel at tasks like the laser cleaning of parts which involve repetition, freeing up employees to work on other activities.

The CleanTech Robotic Cell from Laser Photonics, for example, utilizes a robotic arm that holds a “laser gun” with cleaning, roughening, and finishing capabilities. The robotic arm is programmable via a tablet/controller where the operator would input the coordinates for material processing. The cleaning laser can be replaced with a welding or cutting laser. If required, the workcell can be split into two sections – the robot cleans on one side, while an operator installs a part to be cleaned on the other side.

“The operator can lay out several components for cleaning over the flatbed, set the cleaning coordinates, and leave the robot processing,” explains Tupuola.

He points to advancements in laser technology that complement and expedite the efficient cleaning of such shapes.

“Dual axis laser technology enables the cleaning of target areas more effectively and quickly if they are complex and uneven,” adds Tupuola. “Plus, our proprietary technologies allow the laser to move in various directions and clean hard-to-reach areas.”

Manufacturers of larger format components can find useful laser systems like Laser Photonics’ CleanTech Titan FX, which offers up to a 6’ x 12’ work envelope for automated laser cleaning, rust removal, and surface conditioning. This industrial, turnkey laser cleaning giant can operate as a standalone unit or be easily integrated into a production line environment.

“Large format automated laser cleaning systems can expedite the processing of [applications like] automotive tire rims, molds, oil and gas flanges, or even sheets for the hull of a ship or other vessel,” says Tupuola. He notes that the size and configuration of the enclosures can be customized to accommodate the size and nature of the parts that require cleaning, with the lasers operating at a range of power levels.

Another significant benefit to such automation is improved operator and environment safety.

“For extra safety, our custom-tailored automated laser systems are enclosed in a Class I safety workcell. We can also integrate dust and residue collection, as well as a fume extractor that captures vapors during the cleaning of toxic substances,” says Tupuola.

This type of advanced laser cleaning equipment is designed to accommodate rigorous safety regulations. As an example, Laser Photonics’ CleanTech systems can help businesses achieve compliance with OSHA regulations and make environmentally responsible decisions in accordance with EPA’s waste management guidelines.

Abrasive sandblasting involves forcefully projecting a stream of abrasive particles onto a surface, usually with compressed air or steam. The silica sand used in abrasive blasting typically fractures into fine particles and becomes airborne, which can cause serious or fatal respiratory disease. Particles from the coatings, plating, anodizing, corrosion, and even lead paint being removed can also be inhaled. To avoid breathing in particulates, operators must wear full HEPA suits when sandblasting.

With chemical stripping, harsh chemicals are used to strip metal-based objects of paint, rust, and other contaminants to bare metal – potentially exposing operators to corrosive acids and noxious chemical fumes. In addition, disposing of toxic chemicals is costly and closely regulated. Laser cleaning seeks to solve or minimize these issues.

Unlike conventional methods, the laser cleaning systems require no consumables other than electric power, minimal labor, and minimal maintenance. The longevity and low-maintenance design of these industrial-grade robotic laser cleaning systems further adds to their value, increasing ROI, and making replacement unnecessary for decades.

Programming the laser ablation procedure with a cobot workcell can be accomplished with a touchscreen. Generally, programming includes setting coordinates for the sample, ablation pattern, power output, and cleaning speed, according to Tupuola.

“Installation and programming are needed, but once it’s set up, robotic cell cleaning is fast, precise, thorough, and controlled. So, it’s a very convenient, optimized process if the parts being cleaned are the same,” says Tupuola.

Tupuola adds that Laser Photonics is now working on integrating 3D scanners into the robotic workcell. This would automate the focusing of the laser and eliminate some of the programming now done by an operator.

While precision laser-based systems have been effectively used to remove rust, residues, contaminants, and paint, this approach commonly involves manual labor. Automated robotic laser cleaning systems provide manufacturers safer, easier, more eco-friendly options.

To meet demand more efficiently, a growing number of manufacturers across a wide range of industries will increasingly turn to these laser systems to cost-effectively clean higher volumes of components with the control and speed required for decades to come.

About the Author

Del Williams is a technical writer based in Torrance, California.

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