Metrology isn’t everything – but without metrology nothing is anything

I just want to share to all of you a very interesting editorial piece I received from METAV 2014 team written by Walter Frick, a journalist from WeikersheimWalter Frick. Its about Metrology from all aspects.

METAV 2014 will be showcasing quality assurance within the framework of the Quality Road

To ensure that innovative products are available in the desired quantity, quality assurance within the product creation process must never be the bottleneck. The METAV 2014 in Düsseldorf will be examining this issue from all aspects, and with the “Quality Road” forum will be looking at the latest trends and developments – after all, like health, “metrology isn’t everything, but without metrology nothing is anything!”

Practical quality assurance for optimising processes and products also possesses crucial importance in regard to Industry 4.0 and smart factories. The contribution made by modern-day metrology is succinctly summarised by Stephan Greulich, Sales Manager at Diatest Hermann Költgen GmbH, Darmstadt, as follows: “In metrological systems, information is generated that is of vital importance for quality assurance and thus for the product itself. To ensure that this information meets the stipulations of Industry 4.0 in regard to adaptability or resource-efficiency, it not only has to be acquired quickly, it also has to be promptly interpreted and translated into appropriate action.”

Like all processes involved in a production operation, he continues, the metrological elements also have to be integrated into a network of information that in dependence on all process data and the stipulations entered either formulates decision-making options for the human operator or changes the production processes autonomously. But the next industrial revolution, says Greulich, “is still quite a long way off”. ‘Industry 4.0’ is so far only a term connoting a multitude of intentions and even more expectations”.

It’s perfectly feasible, of course, he adds, to transfer measured data by cable or radio to terminals or web portals, in regard to Industry 4.0, “however, this is at best an interim solution. It is not ‘smart’ in the sense of intelligent or clever, since the measured data are merely transmitted, but this does not necessarily result in a (networked) action”.

Simulation does not replace a practical test
For acquiring and evaluating measured data, he continues, there are already some well-thought-out software solutions today. It is still, however, “the human being who has to make decisions on the basis of data evaluated by the software, and whose stipulations in the software will where appropriate automatically control the production process”.

The expert also has a dispassionate appraisal for the importance of simulation technologies for process optimisation: “Properly planned and well-thought-out simulation technologies can, in some cases at least, replace elaborate test set-ups and trials. However, these will never replace final trialling of a process optimisation in actual practice, since in most cases the reality will be more multi-layered than can be imaged in a simulation.” Greulich sees the “Quality Road” forum at the METAV 2014 primarily as a topical information platform for the latest trends and developments in quality assurance. He would also be interested, moreover, to get some feedback on the expectations expressed by visitors to the fair.

Speed and operator-friendliness are crucial

Heinrich Leutenberger, Subsidiary Manager der Vicivision GmbH, Heilbronn, is singing from the same hymnsheet: “Modern-day metrological technology can ensure fast and accurate information in regard to dimensions and other product characteristics. A stable, effective production process can be achieved only with this kind of information. In this context, speed and in particular operator-friendliness are crucial, because this information also has to be available without specialised expertise.”

Of course, he adds, in large-scale mass production (in the automotive industry, for instance), there are already approaches involving ‘smart’ metrological and testing technologies through portals or smartphone apps, but “by and large this is not yet an issue in dimensional metrology, since as yet the expenditure is not justified by the number of possible applications”.

In dimensional metrology, simulation techniques do not as yet play a significant role for process optimisation, either. Unfortunately, he believes, the potential of modern-day metrological capabilities is not yet being utilised to the full. In his estimation, this is due not least to inadequate knowledge of metrological basics, and to continuing reservations on the part of small and mid-tier companies, in particular, who tend to think that substantial investments in metrological technology should be avoided – “you can’t turn a profit with it...”

From the “Quality Road” forum at the METAV 2014, Leutenberger as an exhibitor expects “above all, of course, that visitors will find it interesting and will perhaps gain a few insights into how modern-day metrological technology can be used”.

Intuitive and intelligent – a highly promising solutional approach
Enhanced transparency and higher measuring and reaction speeds in the quality assurance systems of the future are what Andrzej Grzesiak, Head of Metrology Systems at Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen, expects from Industry 4.0 “with digitisation on the one hand and the use of modern-day man-machine interfaces on the other”. Given the rising levels of complexity involved, “without modern-day metrological and testing technology, proper quality assurance is not possible”. This, however, is increasingly required to adapt to the turbulent production environment involved: “Whether it’s intuitive operator interfaces to the measuring instrument that adapt to human needs or intelligent metrological machines – Industry 4.0 is definitely a most promising solutional approach for the future.”

The influence that Industry 4.0 is having on the development of metrological equipment in industrial production operations is explained by his colleague Dr.-Ing. Dietrich Imkamp, Head of Visual Systems & Partner of Carl Zeiss Industrielle Messtechnik: “Worldwide industrial production processes, in which there is an unbroken trend towards high product quality, are characterised by globally interlinked production chains. In this situational environment, the exchange of information for assuring quality takes on ever-increasing importance.”

The expert was also cautiously optimistic regarding process-dependable options for implementing close-to-production quality assurance in a web-based manufacturing environment – using smartphone apps, for example: “Technologies that we are nowadays familiar with more from the consumer environment will indubitably come into use for quality assurance in the manufacturing environment as well. In this context, however, special requirements will have to be met, for example, in terms of the dependability and security of data transmission.”

In the field of coordinate metrology, too, organised information and communication management is assuming progressively more importance. For this purpose, technologies are needed with which machines, programs, logs and knowledge can be organised at a central location. Most knowledge portals and document management systems, however, are too global, without any optimised functions for coordinate measuring technology. Here, the best option is secure-access, server-based solutions for company intranets, though these have to be amenable to intuitive operation and simple to administer.

Intelligent systems help in quality monitoring
Nowadays, adds Andrzej Grzesiak, a manufacturing company “has to be able to respond swiftly to changes. Thanks to standardisation of the quality processes and the use of software tools, a higher degree of modularisation and flexibility can be achieved for metrological and testing technology. Intelligent systems process data decentrally, and are able to support staff in monitoring quality levels. This is not just futurological dreaming, it’s already possible today”.

Due to the high degree of automation being incorporated into modern-day production operations, the quantity of measured and process data is steadily rising. In order to derive the maximum benefits from this abundance of data, flexible system solutions are required, such as quality data management systems that provide harmonised evaluation and analysis of measured and process data. To quote Andrzej Grzesiak: “Virtual technologies like tablets or data glasses constitute an up-to-the future development trend here. With the aid of virtual technologies, moreover, effective assistance systems can be developed, thus rendering metrological technology more intuitive and more transparent.”

Tactile measuring is among the most commonly used methods for reliably acquiring the shape and condition of cutting edges of high-precision tools and making these data available to the machining process for purposes of optimisation. This measuring job, says Grzesiak, “is nowadays mostly restricted to optical systems operating in planar mode, because the handling and measuring speed involved are significantly better. Tactile methods score in terms of the relatively reliable quality of the measured data, which is independent of the optical surface characteristics.” But in the field of metrology, too, the human factor plays an important role. This is why the measuring machine, as an instrument for quality assurance, has to provide active and intelligent support for the operator.

The Zeiss expert Grzesiak has high hopes of the “Quality Road” forum at the METAV 2014: “Here, in a dialogue between users, the challenges and opportunities of Industry 4.0 will be examined, and new options for modern-day testing and metrological technology mapped out.”

Delcam keeps Bloodhound SSC world record attempt on track

Bloodhound SSC column

Delcam Professional Services has manufactured its first part for the Bloodhound SSC (Supersonic Car) adventure, making the company both an SME Sponsor and a Product Sponsor of the project.  The component is part of the steering support column and so is essential in ensuring that the car remains on track during its world land-speed record attempt.

Bloodhound SSC aims to set a new record of 1000mph in South Africa in 2016. Delcam is supporting the project with its manufacturing software and expertise, as well as producing components for the record-breaking vehicle in the Advanced Manufacturing Facility at its Birmingham headquarters. 

Several Delcam customers and technical partners, including the Advanced Manufacturing Research Centre in Sheffield, are using the company’s CADCAM software to manufacture parts for the ultimate jet- and rocket-powered racing car.

The steering support column was produced on Delcam’s Hermle C50 UMT machining centre, which offers five-axis machining through the incorporation of a trunion for the a axis and a rotary table to provide the c axis. This provides an alternative approach to the DMG, Mazak and Huron five-axis equipment in the Advanced Manufacturing Facility (AMF), and so increases the ranges of processes that can be undertaken and components that can be produced.

As well as providing prototype machining capacity for companies whose own machines are fully occupied with production work, the equipment in the Advanced Manufacturing Facility helps Delcam’s clients to improve their manufacturing processes. These process-development services are attracting increased demand, especially from the aerospace and power generation industries, as many companies now find that their engineering resource is needed to maintain their on-going operations, leaving them limited capacity to introduce new products or develop new processes.

The equipment is also used in testing new developments in Delcam’s software. Being able to test developments on-site on industrial-sized equipment obviously gives Delcam a major advantage in proving out its programs before they are delivered to customers.

The manufacturing expertise gained from the AMF forms an important part of the comprehensive support given by Delcam to all its customers. As well as helping the development teams, the experience gained can be passed on to the support staff. They can use this knowledge to give software users more detailed advice on all areas of their work, including aspects like the best choice of machining strategy and cutter selection, as well as the operation of the software.

BloodhoundSSC

Global companies adopt 3D technology

More and more international corporations are adopting 3D printing technology these days. One example is German firm Siemens AG. The company is using 3D printing to produce components for some of its machines to reduce maintenance time and costs. In some cases, lead time is reduced from 44 weeks to only 4 weeks.

Another company using 3D printing technology is GE Aviation. It plans to print their first metal component for 747Max (BoeingCo. US-BA) and A320neo (Airbus) in the future. According to company specialists, 3D printing can help prolong the life of the components and reduce weight.

Although 3D technology is applied only for certain usages, the technology have many promising areas of potential future application. 3D printing has a bright future not only in rapid prototyping but also in the manufacture of many kinds of metal objects.

Innovation at Schaeffler revolutionizes detent bearing design – combining the bearing support and locking function

Double clutch transmissions attract a high level of attention worldwide and increasingly lead the automotive industry to new and efficient design envelope solutions. Often there is simply insufficient space to apply the locking contours to the gearshift forks and install the detent pins in the transmission housing. This is why Schaeffler offers an integral solution for the bearing support of gearshift elements without affecting the design envelope.

“Schaeffler's new detent bearing offers an alternative solution for locking gearshift forks in situations where the available design space and using conventional detent pins and locking contours is difficult. The detent bearing complements the Schaeffler product portfolio and allows customers to be more flexible when defining transmission specifications,” explains Stanislav Massini, Director of Advance Development and Mechatronics at the Shift Systems Product Line at Schaeffler. The new combination comprising a locking function and a bearing for rotary and linear motion (RLF) provides an interesting alternative for designers, as detent bearings can be integrated into both the outer and center walls of transmissions. Balls used as rolling elements are guided in the stationary cage and ensure a low level of friction in the bearing support. The thin-walled, deep-drawn cup serves as a raceway for the rolling elements at the same time. The integrated spring functions as the detent pin and locks the shifting movement into place by means of the contours on both sides of the shift rod. The spring is preloaded in order to generate a specific retention force that can be adapted to suit requirements.

Even after 4 million load cycles, which equate to more than double the operating life of a gearshift fork, no wear of any kind is visible on the component. The detent bearing continues to function without any problems. The hysteresis characteristics of he new detent bearing correspond approximately to those of a conventional solution– e.g. a rolling bearing support, plain bearing ball detent pin, and locking contour – thus making it a significantly better solution than designs that use plain bearings. The level of integration can be further increased by implementing a sensor in the detent bearing if the gear position of the gearshift fork has also to be detected and the shift travel measured. Measurement takes place in the bearing itself, resulting in
high linearity and measurement accuracy. The integrated connector can be connected both inside and outside of the transmission. This sensor bearing is particularly suited to use in automated manual transmissions such as DCTs and ASGs. The sensor bearing is currently being tested and shows excellent results.

Schaeffler’s new detent bearing offers an integral solution for the

bearing support of gearshift elements without affecting the design envelope.

Opportunities in Indian Railways Infrastructure

Proposed FDI policy could boost the pace of project implementation

Author: Nideshna Naidu

Indian Railways – Overused and underinvested
Indian Railways is the world's second largest rail network and fourth largest freight carrier controlled by a single management. The country's railway network route stretches over more than 64,600 kilometers (km), of which 23,541 km is electrified. The sector plays a critical role in transportation within the country — it operates 19,000 trains every day, moving 2.6 million metric tons (MT) of freight and 23 million passengers.

Though Indian Railways is one of the mightiest networks in the world, it is currently facing capacity constraints and funding limitations. For reasons such as partly improved road infrastructure and lower freight transport costs, road transport is preferred over rail network for freight movement in India and for its last mile connectivity. This is evident from the fact that the share of rail freight movement has dropped from 89 percent in 1950-1951 to 31 percent in 2010-2011. High rail freight cost (approximately 9.1 percent more than road transport) is another factor for this loss. The situation is the same for passenger movement, too.

Exhibit 1: Rail versus Road Freight Movement, India, 1950–2011

Considering the growth of India's commerce and economy and corresponding transport infrastructure needs, the railway sector has always been inadequately funded. Since Independence in 1947, India has added only 11,864 km of new lines according to the Planning Commission of India, with much of the expansion happening in the northern, western, and peninsular parts of the country. Much of the northeastern states in India and regions in the Himalayan foothills lack rail connectivity. Capacity enhancements in the railway sector have always lagged the demand generated by passengers and freight traffic. The railway sector needs investments for adding new lines and associated infrastructure, exhaustive modernization, speed enhancement, electrification, and technological changes to improve services and attract more passenger and freight traffic movement.

Although 72.3 percent of the total rail capacity is utilized for passenger movement, this segment accounts to only 31.2 percent of the total railway revenues. The passenger segment is highly subsidized in India. On the other hand, freight utilizes only 27.7 percent of the capacity but generates 68.8 percent of the total revenues. Most of the revenues earned through freight movement are used to cross-subsidize the passenger segment. This results in low funds to be reinvested in to the system for infrastructure development. In addition, lack of dedicated corridors for freight movement has resulted in low speed of freight transportation, which adds to the loss of revenues, as customers prefer road transport.

Foreign Direct Investments (FDI) – A Catalyst for Growth
Given the current financial scene of the Indian Railways, proposed Foreign Direct Investments (FDI) could bring the much-needed funds for improving the railway infrastructure in India. Although FDI is already allowed in railway component manufacturing, infrastructure development was solely with the Indian Railways. However, with the supply being inversely proportional to the demand, the proposed FDI could boost investments and result in fast implementation of infrastructure projects.

FDI in Indian Railways would facilitate the following:

• Faster implementation of rail infrastructure projects
• Easy movement of goods from mines to ports
• Reliable transport facility for industrial and export growth

Business Opportunities — Aplenty in Rail Infrastructure
The proposed FDI in rail infrastructure would create a huge wave of opportunities for the private sector. So far, Engineering Procurement and Construction (EPC) contractors were executing rail infrastructure projects through turnkey contract awarded by Indian Railways. The major issues in developing railway infrastructure include project delays and cost overrun. Hence, Public-private Partnerships (PPP) is encouraged to bring in investments and, currently, the PPP model funds only 20 percent of the railway projects. PPP based projects are executed by EPC contractors as well. Thus, EPC contractors stand to reap maximum benefits from the proposed FDI, as this would result in fund generation and faster rate of project implementation.
Private sector participation is encouraged in the areas of port connectivity and other infrastructure work, modernization of railway stations, commercial utilization of land, and construction of dedicated freight corridors, multi-modal logistics parks and private sidings, inland container depots, rail side warehouses, and high-speed passenger rail corridors.
While the proposed FDI policy would help in overcoming project delays and cost overruns, enormous opportunities would arise in areas of automation, signal systems, traffic designs and systems, and newer technologies for better and improved efficiency. Key railway segments that could benefit from the proposed FDI include:

• Sub-urban corridors
• High-speed train systems
• Dedicated freight corridors
• Elevated rail corridors
• Rail-port connectivity
• Station development

When the Government of India (GoI) clears the new FDI policy, it would create opportunities for EPC contractors, component manufacturers, technology companies, etc. Though a few phases of the dedicated freight corridors project have already been awarded on turnkey contract model, the project suffers from time delays. The high-speed train systems are also facing similar delays. With the help of FDI, each of these projects would get the required investment, which would translate to business opportunities for EPC contractors.

Application Segments With High Potential for Electronics Manufacturing and Exports

Author: Sagarina Rai

Indian Electronics Manufacturing Market - An Overview
To the Indian Electronics Manufacturing Services (EMS) market, a nation known for its high electronics consumption presents a huge opportunity. EMS is expected to emerge as a vital contributor to the nation's economy.  Expecting the electronics consumption to reach $400 billion by 2020, the government has trained its focus on electronics manufacturing and laid down various initiatives to drive the domestic electronics manufacturing ecosystem to new heights. With a market size of $3.79 billion in 2012, the Indian EMS market is expected to reach a size of $5.39 billion in 2015. The major contribution to the market comes from segments, such as telecom, industrial and consumer goods; the other segments that add to the revenue are healthcare, information technology and office automation (IT/OA), aerospace and defense and automotive.

Indian Automotive Electronics Market Analysis
The Indian automotive industry has made a name for itself as the hub of small car manufacturing destination in the world. India stands second in two-wheeler (2W) manufacturing and fourth in commercial vehicle manufacturing in the world. With a total of 18.3 million vehicles produced in 2011 and 2.0 million exports, India is the sixth largest automobile manufacturing economy in the world, housing 15 manufacturers of passenger vehicles (PV), 9 manufacturers of commercial vehicles (CV) and 16 manufacturers producing 2W.

The Indian 2W industry has shown a strong growth over the last year having grown by 13% in 2011 and is expected to grow at a volume CAGR of 12% by 2015. The passenger vehicle industry is expected to grow at a volume CAGR of 10.8% by 2015 and become the world's fourth largest passenger vehicle market.

Automotive Electronics - Opportunity Analysis
The value of electronics used in an automobile depends on:

• The type of the vehicle: two wheelers (2W), three wheelers (3W), passenger cars, commercial vehicles, electric vehicles, etc.
• The segment the vehicle caters to: entry-level, midsize, premier or luxury vehicle
• Level of automation in the vehicle: manual, power-steering, etc.

Indian-made entry-level cars and 2W have limited electronic content, such as engine monitoring, dashboard display, and few other basic switching controls, which is amply compensated by the high volume 2W and car sales. Premier or luxury vehicles are largely imported as are the high quality electronics used in them.
On an average, the value of electronics that goes into a midsize car manufactured in the country stands at $2,313.19, which is 13.04% of the total value of the car. This value is expected to become higher due to the implementation of stricter emission norms and safety features, such as ECU for 2W and air bags in all passenger cars. Exhibit 1.1 presents the key market drivers and restraints for the automotive electronics market.

Exhibit1.1
Automotive Electronics Market: Market Drivers and Restraints, India, 2014-2018
The total market refers to the demand and supply of automotive electronics in India; this includes both imports and exports. Domestic manufacturing refers to indigenously manufactured electronics, including exports.
The revenues from the total AEM market and domestic AE manufacturing segment were estimated to be $2.87B and $1.54B, respectively, in 2011. The total AEM market and domestic AE manufacturing segment are expected to grow to $4.23B and $2.65B, respectively, by 2015. Indigenous capability augmentation in product segments such as 2W ignition, instrument clusters, 4W engine management systems (EMS), car radios, power windows, flashers, regulators, etc., help sustain the growth in domestic manufacturing revenue.
Exhibit 1.2 depicts the revenue forecast from 2010 to 2015 for the total AEM market and the domestic AEM segment.

Exhibit1.2
Automotive Electronics Market: Revenue Forecast of Total Market and Domestic AE Manufacturing Segment, India, 2010-2015

Ecosystem
India's automotive market has a well-developed ecosystem. From design, development, IP creation, manufacturing, components sourcing, etc., India has developed strengths in all aspects of the automotive industry. High manufacturing and assembly activity in the Indian automotive market continues to set new benchmarks. The following automotive products have been considered top priority, based on the following scope:

• High revenue generation
• High domestic manufacturing
• High value addition - raw material sourcing, R&D capability, IP creation in India

Future Outlook for Automotive Electronics Market in India

• Owing to the huge untapped rural market, the demand for automotive electronic is like to rise, presenting a large domestic market.
• India is an emerging small car manufacturing hub with great R&D capabilities.
• Introduction of new technologies, inclusion of more electronics switches, lighting, shift from CDI to ECU in 2W, analog to digital controls and growth of EMS and ABS are the new additions which will spur the consumption of automotive electronics.
• Increasing uncertainty in fuel pricing is expected to boost the demand for electric vehicles during the forecast period, thereby leading to greater consumption of automotive electronics.
• The Indian Government's initiative in mandating Bharat Stage IV norms and fuel efficiency labelling for all vehicle categories has encouraged manufacturers to discontinue or modify their older engines to suit new norms, thereby, creating fresh avenues for automotive ignition electronics market.
• With 100% Foreign Direct Investment permissible in the automotive sector, there is increasing investment in both 2W and 4W segments, be it the setting up of new plants or R&D centers, etc.; this increases the demand for auto electronic components. 

Renishaw inspires new generation of scientists and engineers

Renishaw, the internationally recognised engineering company, has renewed its sponsorship of The Big Bang Fair as part of its ongoing commitment to develop the UK's next generation of engineers and scientists.

The Big Bang (UK Young Scientists & Engineers) Fair, which this year takes place at the NEC, Birmingham from 13 – 16 March, is the largest celebration of science, technology, engineering and maths (STEM) for young people in the UK (primarily aged 7 to 19), and aims to highlight the many exciting and rewarding opportunities available with the right experience and qualifications. At the fair, visitors will experience a wide range of entertaining theatre shows and interactive exhibits, as well as having the opportunity to meet some of the country's leading scientists and engineers.

In sponsoring the Big Bang Fair, Renishaw is continuing its commitment to raising awareness surrounding Engineering as a career. The Company's Education Liaison Executive, Julie Collins, explains, “It is increasingly important that we encourage young people to study subjects that will give them the qualifications that they will require for an interesting and rewarding career in engineering and science. Events like the Big Bang Fair really help to spark the interest of young people and inspire them to keep studying STEM subjects.”

This year the Renishaw stand will feature a Renishaw Equator gauging system, enabling young people and their teachers to interact with measurement machinery rarely seen outside of an industrial facility. Visitors will be encouraged to directly control the machine with the aim of navigating a 3 dimensional maze in the shortest amount of time; a prize will be given for the fastest time each day.

In 2013, the Big Bang Fair hosted 65,000 visitors of all ages, who both enjoyed and learned from their experiences. The organisers reported that over 76% of 12 – 14 year olds viewed engineering more positively as a result of their visit. Renishaw is working with education establishments and national skills providers to both promote the importance of STEM subjects and careers in science and engineering to help combat the nationwide shortage of skilled individuals.

The Big Bang Fair is delivered by over 170 organisations from the public, private and voluntary sectors, including EngineeringUK, the British Science Associate and the Institute of Physics. Booking is now available online at www.thebigbangfair.co.uk.