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In this issue:MESNZ honours Bill Buckley page 36
How Nevaleak created the grease coupler and nipple that won’t leak, wear or jam page 14
Women in engineering page 20
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WORKSHOP 49
November 2014 www.engineeringnews.co.nz
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Sponsored article
Future proofing the manufacturing industry at IMTS 2014
Ensuring the industry attracts a young and
energetic workforce was a key theme of the
show. With interactive demonstrations and
projects, attendance at the IMTS Smartforce
Student Summit more than doubled
compared to 2012 and provided nearly
18,000 students, teachers and parents with
a fun insight into developments and careers
in manufacturing. “There were excited
young people everywhere, it was great to
see the enthusiasm for the industry. If these
kids are the future then we don’t have to
worry!” says Aotea Machinery’s account
manager Karl Medley.
“There was a universal vibe during the show
among exhibitors, visitors and even students,
that manufacturing is THE place to be”, said
Peter Eelman, AMT Vice President –
Exhibitions and Communications. “Even
more exciting to exhibitors was the fact that
customers came with buying intentions, and
a confidence that has not been seen in the
manufacturing industry in many years.”
Machinery giant Haas was one such
company seeing records set at the show.
“Haas had the highest lead count ever at this
year’s show and orders were taken for over
100 machines and we received over 900
enquires in just one day”, Karl Medley adds.
Eighteen of their latest machines were on
display on the 10,000m2 stand, with the
company owner Gene Haas climbing over
the equipment and talking shop with visitors
from across the globe. Their big winners
were the new UMC-750SS and ST-55
machines which will be available to the New
Zealand market in the new year - exclusively
through Aotea Machinery. The UMC-750SS
is a high speed, 40 taper, 5 axis machining
centre with 30”x20”x20” travels and
15,000rpm inline direct drive spindle, whilst
the ST-55 is long bed turning centre with a
12.5” diameter through-bore and a 55hp
vector dual-drive unit powering the spindle
through a Haas built two-speed gearbox
providing 4,250ft-lb of torque in low gear.
“If there’s one thing I took from the show
it’s that Haas is the first choice for machinery
across the world. Their reputation thrives on
service and innovation, something dear to
any Kiwi manufacturing company’s ethos”
says Karl.
Haas plans to capitalise on this global
interest in manufacturing and is focusing on
further developing the brand across new
markets with the goal of achieving a $2
billion USD turnover by 2020. For customers
in New Zealand, this means access to Haas’
latest machines and full support packages
supplied by technicians trained in the Haas
factory. “Haas is helping New Zealand
companies get the most out of advances in
manufacturing technology, it’s great to be
part of ensuring the industry here remains
strong and continues to compete on a global
scale”, Karl concludes.
For more information, contact Karl on
09 526 8307.
Haas’ new line of machinery attracts attention.
Students check out one of many demonstrations at the Smartforce Student Summit.
The future of manufacturing materialised before the eyes of visitors to the 30th International Manufacturing Technology Show (IMTS) in Chicago on the 8th to the 13th of September. 112 countries and 2,035 companies were represented in over 1.3 million square feet of exhibition space.
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ENGINEERING LEADERS 5
November 2014 www.engineeringnews.co.nz
“Materials and composites science and en-
gineering is all about understanding why
solid materials behave like they do and how
to improve them,” Professor Pickering, the
deputy head of the School of Engineering, at
the University of Waikato, says. The essence
of this work is manipulating the properties
of composite materials and natural fibre
composites and modelling their failure, to
create substances with which producers
can do more in today’s high-technology
environment.
Professor Pickering says she has drawn a
lot of inspiration from nature for her work.
“Think of the capabilities of objects such as
trees and shells, the combination and design
of material properties in nature and the way
they function, that we cannot imitate yet.
Think of our bodies – we cut ourselves, and
our bodies self-heal. In materials science and
engineering, these are the kind of proper-
ties we study, the kind of objectives towards
which we are working,” she explains.
Professor Pickering, following her enjoyment
of and outstanding results in science, math-
ematics and craftwork, first interviewed at
the Imperial College of London, where her
brother was studying mechnical engineer-
ing, for chemical engineering. “While there,
I was introduced to materials, and a whole
new world opened up for me, so materials
is what I did,” she recalls. In 1987 she com-
pleted a BSc(Eng) degree.
After four years working for a tele-
communications company, developing
interconnectedness technology by manip-
ulating the qualities of silicon and gallium
arsenide chips for the purposes of refining
thermal imaging systems, she went back to
school in 1991. In 1994 she completed her
PhD in composite materials at Surrey Univer-
sity, then headed towards New Zealand and
a job at the University of Waikato.
This was a leap of faith; when she joined
the staff, there were only three other people
working in the engineering department.
Twenty years on, there are now about 20 ac-
ademic staff members, including a team of
staff dedicated to materials research.
“From the houses we live in and the cars we
drive, to the computers and smart phones
we use, much of our daily activity, comfort
level and to a large degree, even happiness,
relies on our interaction with materials. In
addition, materials science and engineering
is a key driver for technological development
and national economic success,” Professor
Pickering comments.
She explains a key focus for the team of
students and researchers is therefore meas-
urable value addition to the economy by
supporting companies with the develop-
ment of composite materials and polymers
for specific applications. Several of these
research projects stand out for her. Past
successes include a rotationally moulded
weighbridge for livestock, developed in
conjunction with an agricultural supplies
company, and a corrosion-resistant com-
posite used for the storage of petroleum
developed in conjunction with a construc-
tion product producer.
Her favourite projects however are those
involving developing sustainable composite
systems and complementary bio polymers
from natural fibres. One of the products
resulting from that field of study is plastic
clip systems for meat production processes
made from corn gluten meal. Another is sus-
tainable composites for use in 3D printing,
a field in which the team is a world leader.
“We’re looking at developing materials to
give improved performance, using cheaper
systems that more people can access in the
near future. We’ve done some work looking
at reinforcing plastics with sustainable ma-
terials, or using sustainable materials only,
so we can move beyond printing prototypes
to actually making parts that are strong and
stiff enough for in-service use.
“So far we’ve shown we can 3D print com-
ponents from sustainable materials that are
stronger than injection moulded parts, ideal
for one-off and personalised parts, such as a
custom-fitted exoskelet for a broken wrist or
replacing simple broken parts on household
appliances,” she says.
The team also works with Hemptec, a tex-
tile producer, to investigate the potential
of using hemp fibres and New Zealand
harekeke flax in composite materials. A
major market for this kind of work is the
European automotive industry, who uses
this technology for vehicle interior styling to
comply with end-of-life recycling directives.
But Professor Pickering’s pride and joy is a
research project that looks at ways of rea-
ligning fibres in composites to strengthen
building materials. “We’ve had huge suc-
cesses in improving the properties of these
materials. Previously fit to be used for low
structural requirement purposes only, we
now see them so enhanced in strength, stiff-
ness, and load bearing capacity, that they
can be used potentially in applications such
as bridges and airplanes,” she says.
The results are measurable and exciting. A
biodegradable, recyclable, natural short-fi-
bre composite material from the team’s
laboratory has been tested to yield at 100
mPa, compared with common wood tested
parallel to the grain – its strongest point –
yielding at 35-50 MPa and mild steel yielding
at 220 MPa. The steel, however, weighed six
times as much as the composite material,
which leaves the field wide open for novel
applications.
But even more exciting are the results from
the team’s experiments with self-healing
composites. So far, modified carbon expoxy
has proved its ability to self-heal cracks
by reknitting the affected molecules in a
process stimulated by heat application. “Al-
though we’re not getting a 100% return of
strength, it significantly prolongs the life of
the material…and we’re not finished with
the research yet,” Professor Pickering smiles.
She says, since the team’s role is often
supportive to ensure the success of client
companies and the university as a rule does
not make its own products, it is often diffi-
cult to claim credit for successes.
“Our work is behind the scenes. But I am a
natural engineer, I see problems and want to
solve them, like to solve them. As a group
we want to make things better, so knowing
we made a difference is enough in itself,”
she adds.
Professor Kim PickeringKeeping it sustainableAll the objects people use in their daily lives, nature-made or man-made, consist of material, and there is always room for improvement. A fascination with this observation and a passion for science, mathermatics, and craftwork is what turned Kim Pickering’s mind to a career as materials and composites science engineer.
Professor Kim Pickering
www.engineeringnews.co.nz November 2014
6 THIS ISSUE
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ISSN 0110-6880 (Print)
ISSN 2324-3155 (Online)
News and CommentaryGallagher wins big at New Zealand Plastics Industry Awards (P8). Altium and Aras partner for next generation ECAD/MCAD collaboration
in PLM environments (P8). Kinetika festival winners wow judges (P9). Hypertherm has appointed Israel Gonzalez regional director for the
Asia Pacific Region (P10). Free access to proven processes for New Zealand Councils (P10). Millennium Plastics takes out Supreme Award
at Plastics Industry Design Awards (P11). Nineteen projects are finalists in the New Zealand Engineering Excellence Awards 2014 (P11).
University of Waikato engineering students have created a prototype for commercial picking of pine tree seedlings (P12). Steel fabrication
industry meets its most significant challenge (P13).
Special Feature – Engineering Leaders: Professor Kim Pickering: Keeping it sustainable (P5). Engineering in the food industry: Prominent food pro-
cessing plants install Europress Piping System (P18). Cedenco Foods selects Fortinet Access Points for major expansion (P19). Women in
Engineering: Engineering yields to family needs: Nancy Chow, Maire Lenihan, Suzanne Naylor, Nicky Smith, Simonne Eldridge and Sarah
Sinclair tell their story (P20, 21 and 22). Dr Filicia Wicaksana makes advances in membrane technology (P20). Susann Beier is engineering
stents to improve treatment of heart disease (P22).
AutomationNational Instruments (NI) has launched a new software solution for machine maintenance and operations (P16). Aurora has added the
Fuji range of robotic palletising systems to its range of process equipment (P16). ABB provided a solution that is cutting costly outages for
Fonterra (P17)
DesignCase Study: How Nevaleak created the grease coupler and nipple that won’t leak, wear or jam (P14). Some design challenges in the
award-winning Gallagher T20 Terminal (P24).
WorkshopDMG MORI’s LASERTEC 65 3D incorporates generative laser deposition welding into a fully-fledged 5-axis milling machine (P23).
Monthly print figure as at November 2014: 9,000
November 2014 www.engineeringnews.co.nz
THIS ISSUE 7
Women in Engineering Engineering yields to family needs: Nancy Chow, Maire Lenihan, Suzanne Naylor, Nicky Smith, Simonne Eldridge and Sarah Sinclair tell their story (P20, 21 and 22). Dr Filicia Wicaksana makes advances in membrane technology (P20). Susann Beier is engineering stents to improve treatment of heart disease (P22). Professor Kim Pickering: Keeping it sustainable (P5)
Power SystemsHyspecs builds solutions from scratch (P29).
MaterialsLiquid tight plugs are one of the latest additions to Hi-Q’s range of plugs and caps (P10). Jim Colt of Hypertherm talks about how to de-
termine the best process for metal cutting (P26 and 27).
MachineryFuture proofing the manufacturing industry at IMTS 2014 (P3).
EnvironmentOpus Research built a brand new boundary layer wind tunnel; the only commercially owned and operated wind engineering facility in New
Zealand (P30). The OptiFlex®2 B puts the world’s most advanced technology in this field in the palm of the operator’s hand (P31). James
Walker eliminates noise and shock problems on industrial pipe and plant installations (P36).
ManagementNew problem-solving cards provide a “brain hack” for product creators (P33). National Maintenance Engineering Conference: Step
change for iconic Maintenance Engineering Conference (P35). Maintenance Society honours Bill Buckley (P36). Call for papers for VANZ
2015 Conference (P38).
NZ Engineering News SupportersAccess Solutions (P11), Anco Print (P24), Aotea (P3), Aurora Agencies (P16), Autodesk (P7), Bailey Tanks (P30), Bay of Plenty Polytechnic
(P33), Brevini (IFC and IBC), Competenz (P9), DMG MORI (P23), Eurotec (P37), Forklift Solutions (P11), Haas Automation (P3), Hi-Q Com-
ponents (P10), Hyspecs (P29), Industrial Air Systems (P13), James Walker (P36), Kiwi Asset Finance (P1), LEP Engineering Plastic (P26),
Machinery House (OBC), Machinery Seller (P21), MESNZ (P34), Monocrane (P28), Mono Pumps (P15), NHP Electrical Engineering Products
(P4), RasterTech NZ (P12), RR Fisher (P28), SICK (P8), SPX (P19), Steel & Tube (P27), Strouds (P31), Thermaclad Insulations (P30), Total Lu-
bricants (P1), VANZ (P38), Waikato Bearings (P35), Waterworks Wholesale (P18).
www.engineeringnews.co.nz November 2014
8 NEWS
SICK WORKS WELL UNDER PRESSURE
For more information please visit www.sick.co.nz or call 0800 222 278 (Tollfree).
Altium Ltd, a global player in electronic
design automation, native 3D PCB design
systems (Altium Designer) and embedded
software development toolkits (TASKING),
has announced a partnership with Aras, one
of the leaders in enterprise product lifecycle
management (PLM), to provide advanced
PLM capabilities to ECAD design teams.
Based on Altium’s solutions for collabora-
tion and ECAD design management and
Aras’ suite of PLM solutions, both compa-
nies will work on a new approach to fully
integrate MCAD-ECAD PLM workflows
for companies with systems engineering
requirements and complex mechatronic
product development environments.
“Team collaboration and ECAD design
management are fundamental needs in
today’s electronic design environments,”
says Altium chief technology officer Jason
Hingston. “The partnership with Aras will
provide design engineers and the teams
in the broader organisation with a new
level of integration in an ECAD/MCAD
environment.”
Aras president Peter Schroer says the de-
velopment of next generation products
combining electronics and software is re-
sulting in greater complexity during design
and manufacturing. “Altium’s perspective
At a gala dinner, held on October 3 in Auck-
land, Gallagher was awarded Gold for Tool
Making, Gold for Co-Moulded Injection
Moulding, and Silver in the Industrial prod-
uct category.
“We’re delighted at winning three acco-
lades at this year’s New Zealand Plastics
Industry Design Awards,” says Gallagher
Security chief technology officer Steve Bell.
“The T20 is a product we’re extremely proud
of, and for our team, this recognition is well
deserved.”
The New Zealand Plastics Industry Design
Awards brings together companies from
around the country who are involved in
the design, production, and marketing of
plastics products. The awards showcase the
best in innovative plastics design and man-
ufacturing. Entries are judged not only on
concept, design, commercial performance,
major industries including education, ports
and airports, military and defence, critical
infrastructure, mining, corrections, finance,
Altium and Aras partner for next generation ECAD/MCAD collaboration in PLM environmentsPartnership provides a multidiscipline approach for unified MCAD-ECAD product development of sophisticated mechatronic systems.
on the need to bring together the electron-
ic and mechanical design processes aligns
with ours, providing us the opportunity to
jointly build better PLM processes for today’s
modern manufacturers.”
and export potential, but increasingly on
enhancing environmental sustainability
through the product’s life cycle.
Gallagher’s security solutions are regular-
ly recognised for quality and innovation in
awards across the world. The Gallagher T20
Terminal was released to the global security
market in July 2013.
The Gallagher Group, internationally re-
nowned for their Animal Management
and Fuel Systems divisions, entered the
security market in the early 1990s. Lever-
aging their strength in research, design,
and development, the privately owned and
operated NZ company has grown to be a
global technology leader in the develop-
ment and manufacturing of integrated
security solutions. Gallagher’s security solu-
tions are utilised in more than 100 countries
around the world, and are employed in all
entertainment, and healthcare.
See related article on page 24
Left to right: Mathew Bell, Steve Cormack, Callum Ferguson, Cris Dorlas and Marty Blake
Gallagher wins big at New Zealand Plastics Industry AwardsGallagher, an international leader in the design and manufacturing of security products, was awarded prizes in three categories for its intelligent card and PIN access control device – The Gallagher T20 Terminal – at The New Zealand Plastics Industry 2014 Design Awards.
NEWS 9
November 2014 www.engineeringnews.co.nz
0800 526 1800 www.atnz.org.nz
The hassle free apprenticeship serviceContact Apprentice Training New Zealand to find out how we can recruit, employ and manage apprentices to train in your business.
Kinetika, organised by The Taranaki Arts
Festival Trust, received nearly 70 entries,
giving the judges a tough process of se-
lecting winners and runners-up across five
entry categories, says festival manager Lisa
Haskell.
“We have had an amazing selection of en-
tries from designers of all ages, all abilities
and from all over the world as well as New
Zealand,” Ms Haskell says. “With the sup-
port of local engineering firms, we have
been able to develop and build nine entries
and display these to the public.”
The Supreme Award winners in Catego-
ry One: You Design & Build were Raewyn
Turner and Brian Harris of Auckland with
Towards the Mean – 23 tin cans filled
with various fragrant soils sitting on a
beam. The work references to the Expec-
tations-Augmented Phillips curve that
describes a relationship between inflation
and unemployment.
The Supreme Award winner in Catego-
ry Two: ITL’s You Design & We Build was
Nastassja Imiolek of Auckland with Only
the Essence Remains. Fabricated by Wells
Group, Nastassja described her original
concept as being “like a kind of big bubble
made by paper folding (tessellation) with a
little motor inside.”
Highly Commended in this category was
Feather Fall by Sam Hagmann from Tarana-
ki. Fabricated by Howard Wright Ltd,
Feather Fall is a structure that collects feath-
ers at the bottom and releases them at the
top, from where they gently fall down again
and again in a continuous motion.
And receiving the Commended Award in
this category was Pure New Zealand by Jia
Fang from Wellington. Fabricated by Rivet
engineering company, Pure New Zealand is
a silver fern created by a series of vertical
stainless steel tubes, bubbling water and
mirrored in water to create a complete
silver fern in an elegant and spirited way.
The intention of the work was to express
the pure and clean nature of the New Zea-
land environment.
In Category Three: Great Ideas the Supreme
Concept Award went to Timo Khalen from
Germany for Dance for Insects. The Highly
Commended Concept Award went to
Amanda Firman from Wellington for Just
Breathe. And the Commended Concept
Award went to Jozsef Tasnadi from Hungary
for The Visitor.
The Supreme Award winner in Category
Four: Taranaki Student Design & We Build
was Scared Animal by Matthew Tait from
Highlands Intermediate School, which was
fabricated by EHL Group. The Highly Com-
mended Award went to Swan, designed
by Highlands Intermediate School student
Andrew Coles and fabricated by Steelfab
Ltd. The Commended Award went to The
Blind Clock designed by Kiana Armstrong
from Coastal Taranaki School and fabricated
by Wells Group.
And the winner in Category Five: Student
Design & We Build was A Matter of Time
designed by Hawera High School student,
Rebecca Pratt. Developed and built by Wells
Group engineer Leith Robertson, Rebecca’s
concept was inspired by the debate about
iron sand mining off the Taranaki coast. The
working prototype features an hour glass
filled with iron sand which rotates automat-
ically every hour.
“What’s wonderful about kinetika is that it
enables creative freedom for the designer
to express themselves within the competi-
tion guidelines and can bring about some
amazing creations through unique collabo-
rations,” says Ms Haskell.
The Great Ideas design concepts are on
display inside Puke Ariki, while entries in
the design and build categories are on
display both inside and on the landing in
front of Puke Ariki. Artworks in this year’s
Kinetika competition will be auctioned on
November 9.
Kinetika festival winners wow judgesKinetic art designs powered by solar, wind, water, electricity and human energy have wowed judges and audiences alike in the 2014 Kinetika festival, a competition showcasing kinetic art, design and engineering running from October 25 to November 9 in New Plymouth, Taranaki.
Raewyn Turner and Brian Harris with Towards the Mean Jia Fang and Pure New Zealand
www.engineeringnews.co.nz November 2014
10 NEWS
0800 766 709
H_2
370
Mr Gonzalez joined Hypertherm Mexico
in 2008 as a consumable sales manager. In
2010, he was promoted to lead the Mexican
team, where he demonstrated his impressive
organisational skills, excellent knowledge of
Hypertherm’s products and their applications,
and strong team management capabilities.
Prior to joining Hypertherm, he was the cus-
tomer solutions manager for Festo Pneumatic
S.A. and led a team of 16 associates, based
throughout Mexico.
“Over the last six years, Mr Gonzalez has
proven to be a competent leader and has
contributed significantly to the expansion
of the Mexico team,” Hypertherm Interna-
tional vice president Pete Vickers says. “With
his expertise and years of experience, we are
confident that he will bring new perspectives
and a fresh approach to his new team, and
take Hypertherm Asia Pacific to the next level
of business success.”
Mr Gonzalez holds a Master’s degree in
Mechanical Design and Robotics from the
Universidad Nacional Autonomá de México.
He will be responsible for the continued
development of the full spectrum of sales,
service, logistics, financial administration and
Hypertherm’s go-to-market strategy in Asia
Pacific, a rapidly emerging and strategically
important market.
Hypertherm designs and manufactures ad-
vanced cutting products for use in a variety
of industries such as shipbuilding, manufac-
turing, and automotive repair. Its product
line includes plasma, laser and waterjet cut-
ting systems, in addition to CNC motion and
height controls, CAM nesting software,
and consumables. The 100 percent associ-
ate-owned company, consistently named one
of the best places to work in America, has
more than 1,300 associates along with oper-
ations and partner representation worldwide.
Hypertherm appoints new Asia Pacific regional directorHypertherm, a US-based manufacturer of plasma, laser, and waterjet cutting systems, has appointed Israel Gonzalez regional director for the Asia Pacific Region, which covers New Zealand and Australia, among others.
Israel Gonzalez
Manufactured from black UL94 V0 silicone
rubber these plugs provide an IP67-rated
liquid-tight seal. These are available in seven
different sizes with mounting holes from
12.7mm to 34.93mm and to suit maximum
panel thicknesses of 3.2mm. These plugs
are easy to install with just fingertip pressure
– no tools are required.
Alongside the range of liquid-tight plugs is a
range of grommets and bushes. Grommets
are used to protect or cover through holes,
helping eliminate sharp edges so wires and
cables are protected. One of the most pop-
ular, polyethylene grommets, come in clear
and colour and have an easy-fit design into
panel holes from 6.3mm to 38.1mm. A
range of rubber grommets is available for
panel holes from 4.8mm to 31.7mm and fit
panel thicknesses up to 1.6mm.
Hi-Q stocks multiple variations of bushes in
miniature, standard, adjustable and open/
close styles. Adjustable bushes close the
entry hole to insects and vermin and adjust
to accept various diameters and shapes.
Open/close bushes are designed for uneven
drilled or punched holes and can be installed
after the cable.
Bushes are manufactured from black nylon
6/6 and are designed to snap quickly into
the panel hole, and fit panel holes from
4.8mm to 50.8mm.
If you are looking for that hard-to-find plas-
tic hardware, it is hard to go past Hi-Q. the
company seem to have something for every-
one looking to fix, fasten, clip, tie, insulate,
mask, protect, plug, cap or finish.
Contact Hi-Q Components for free product
samples and catalogues.
For more information:
Phone: 0800 766 709
Email: [email protected]
Visit: www.hiq.co.nz
Sponsored article
Liquid-tight plugs, grommets and bushesLiquid-tight plugs are one of the latest additions to Hi-Q’s range of plugs and caps.
The Local Government Shared Process Li-
brary NZ consists of around 1000 processes
developed by councils and uploaded to the
cloud for sharing. The library is supported
by business process management software
provider, Promapp, and includes processes
for activities where there is high public in-
terest such as building consents, resource
consents, wastewater management, en-
vironmental health and environmental
monitoring, and liquor licensing. The
library also includes an extensive set of pro-
cesses for dealing with land information,
parking, libraries and museums, recrea-
tion and leisure, community development,
animal management and compliance as well
as customer services and service delivery.
“Anyone with a council email address will
be able to access the Local Government
Shared Process Library NZ,” says Promapp
co-founder Ivan Seselj. “Councils from all
over the country have submitted 1,000
processes to share with all other councils.
Taken together these processes represent
the results of many thousands of hours of
analysis, documentation and review. Coun-
cils will be able to use the library to gain
detailed insights into the way other councils
operate and improve their own processes,
performance and customer service.”
All processes in the library were developed
by councils using Promapp software.
“We were happy to share our entire build-
ing consent authority quality assurance
process with other councils,” says library
champion, Jamie Dale of Taupo District
Council. “We’ve invested heavily in trying to
keep it simple and effective, which allows us
to focus on delivering building control ser-
Free access to proven processes for New Zealand CouncilsThis November, local councils throughout New Zealand will gain free access to a new online library that allows them to share their knowledge and experience with other councils.
vices to our customers.
“IANZ have reviewed the complete process
and accredited it as meeting the require-
ments of the Building (Accreditation of
Building Consent Authorities) Regulations
2006. Local government has a remarkable
history of cooperation. Sharing proven, val-
uable resources is a natural extension of that
culture.”
Council staff can request access to the
library from http://www.promapp.com/
lg-shared-process-library or email lgpro-
NEWS 11
November 2014 www.engineeringnews.co.nz
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The company also took out Gold Awards in
both the Primary Product and Conventional
Injection Moulding Process categories.
“We are extremely honoured to receive
these three awards. It is great validation for
our staff, who are truly the very best in New
Zealand,” Millennium Plastics general man-
ager Tony Rutz says.
“At Millennium Plastics, we do things a bit
differently. We’re not simply another plastics
design and moulding company. Our exper-
tise lies in working side-by-side with our
customers to ensure their original product
ideas and designs capture the greatest value
for their business and achieve the product
benefits they promise their customers.”
Waikato Milking Systems’ new Electronic
Milk Meter provides accurate real-time milk-
ing data, enabling dairy farmers to improve
herd management decisions and long term
profitability of their herds.
Product design manager Jim Pharaoh says:
“Our first concepts for our electronic milk
meter were developed several years ago.
Several prototypes were trialled on farms
resulting in a computer model that was
submitted to Millennium Plastics for their
critique and manufacture of the meter
which was released to farmers in August
this year.
“The modern milking shed is a very chal-
lenging environment to design for as you
need to develop products to withstand con-
tact with milk, heat, cleaning chemicals and
moisture. Over the years we’ve found that
with careful material selection we can satisfy
all those criteria while also injecting a high
level of innovation and creativity into our
product designs.
“Simplicity is the cornerstone of Waikato
Milking Systems’ design philosophy and
the modern plastics technology Millennium
Plastics uses allows us to make very complex
forms to create simple, effective products.
The end result is that we supply products
to our customers that are both reliable and
fit-for-purpose.”
Jim Pharaoh of Waikato Milking Systems, left, and Tony Rutz of Millennium Plastics
Millennium Plastics takes out Supreme Award at Plastics Industry Design AwardsHamilton-based Millennium Plastics was awarded the overall Supreme Award at the 2014 Plastics Industry Biennial Design Awards for their contribution to the design and development of Waikato Milking Systems’ all-new Electronic Milk Meter.
Millennium Plastics specialises in the design,
development, and manufacture of high-end
plastic products. It works with clients in a
range of industries, including dairy, animal
health, electronics, medical and safety.
The finalists are:
• Christchurch Airport Artesian Heating and
Cooling: Beca
• The Clutha Gold Trail, Otago: Southern
Land, Ocel Consultants, Kopuwai Consult-
ing, Geoconsulting Ltd
• Three35 Office Buildings: Ruamoko
Solutions
• SKOPE Cooler: SKOPE Industries
• A Pres-Lam Assertion in Damage Resistant
Design: Kirk Roberts Consulting Engineers
• Christchurch Biosolids Drying Facility: Beca
• Eastern Selwyn Sewerage Scheme: MWH
New Zealand
• Wellington Trolleybus Overhead Protection
Project: Wellington Cable Car Ltd, Pro-
Techtion Consulting, Greater Wellington
Regional Council, RCR Infrastructure –
O’Donnell Griffin
• Taupo Water Treatment Plant: Beca
• Mapua Wharf Wastewater Pump Station:
MWH New Zealand
• Te Matau – Pohe: McConnell Dowell
Constructors, Transfield Services, Novare
Design, Gaia Engineers, Knight Architects,
Eadon Consulting, Northern Civil Consult-
ing and Whangarei District Council
• Matangi Electrical Multiple Unit Project:
Greater Wellington Regional Council,
CH2MHill
• Christchurch Airport Gilsonite Works:
Christchurch International Airport,
AECOM NZ, Fulton Hogan
• Fonterra Darfield Site: Fonterra Cooper-
ative Group, GEA Process Engineering,
Ebert Construction, Calder Stewart, Fulton
Hogan, Babbage Consultants
• HVD Pole 3: Aurecon NZ Ltd, Siemens NZ,
Transpower NZ
• Amethyst Hydro Power Generation
Scheme: ElectroNet Services, Amethyst
Hydro, Mitton ElectroNet
• Tekapo Canal Remediation: Genesis
Energy, URS, Carpi Tech, Fulton Hogan
• Taharoa Buoy Relocation and Pumphouse
Upgrade: McConnell Dowell Constructors
Ltd, New Zealand Steel Mining
• Christchurch Southern Motorway Stage 2:
GHD, Beca
• Tawa Railway Station Project: Greater Wel-
lington Regional Council, Aurecon
• Cashin Quay 1 Earthquake Repairs: Opus
International Consultants
• AMETI - Panmure (Auckland Manukau
Eastern Transport Initiative): Opus Interna-
tional Consultants
• We're Going Home Safe Every Day: Fon-
terra Cooperative Group, GEA Process
Engineering (NZ), Ebert Construction,
Calder Stewart, Fulton Hogan, Babbage
Consultants
• Making Safety Pay: Fulton Hogan
• Comfort Group Machinery Safety Pro-
gramme: BVT Engineering Professional
Services, The Comfort Group
Short videos and some finalists can be
viewed at:
www.nzeeawards.org.nz
www.youtube.com/engineersnz
NZ Engineering Excellence Awards 2014 finalistsNineteen projects are finalists in the premier engineering awards, New Zealand Engineering Excellence Awards 2014. Winners in the People, Projects and Products, and Practice categories, along with the Supreme Award, will be announced on November 28th at the Pullman Hotel in Auckland.
www.engineeringnews.co.nz November 2014
12 NEWS
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As part of a third-year mechanical engineer-
ing design paper, 10 teams of students were
each asked to create a prototype machine
that could collect nine metal pins along
a track, then reverse and drop the pins in
a box at the end. The process is designed
to emulate the act of picking pine tree
seedlings.
The winning team’s prototype collected
and deposited the most pins in the fastest
time. The inventions were tested at the
Carter Holt Harvey Pulp & Paper Engineering
Design Show in October.
The winners on the day were Gordon Jack-
son (Paeroa College), Ben Plumtree (Hawera
High School), Nate Ryan and Mark Edwards
(St John’s College Hamilton) with their ve-
hicle named Zeus, which stood out for its
speed and accuracy.
“We think our success was down to utilis-
ing the electrical circuits to allow maximum
voltage through each motor,” says team
member Mark Edwards.
Course lecturer Associate Professor Mike
Duke says the project is a great way for the
students to work on something from start to
finish. “It’s their first chance to experience
the development of a functioning machine
right from concept, to design and build.”
The project is part of a much wider research
collaboration with tree improvement and
treestock production business ArborGen
Australasia. Last year students worked on
prototypes that could distribute one pine
tree seed in each compartment of a seed-
ling tray in the shortest time. In addition Prof
Duke’s research team completed a Dibbler
machine which plants seedlings so that they
grow straight.
“Picking the seedlings in a mechanised way
is just another step in our research project.
For the students we simply asked them to
make machines that could collect seedlings,
but what we’re working on at a higher level
is creating a prototype which uses machine
vision systems to grade the seedlings as it
collects them.”
The Carter Holt Harvey Pulp & Paper Engi-
neering Design Show ran on October 21
and 22. The event was sponsored by Carter
Holt Harvey Pulp & Paper, PDV Consult-
ants, the Institute for Professional Engineers
New Zealand (IPENZ) Waikato/Bay of Plenty
Branch, the University of Waikato’s School
of Engineering, SENZ (the student division
of IPENZ), Tetra Pak, Gallagher Group, MEG
(Mechanical Engineering Group) and Coup-
land’s Bakeries.
Mark Edwards, kneeling, with the winning prototype at the Carter Holt Harvey Pulp and Paper Engineering Design Show
Winning team, from left, Gordon Jackson, Ben Plumtree, Mark Edwards and Nate Ryan
Pick up sticks – engineering stylePicking commercial pine tree seedlings is about to get a whole lot easier thanks to a class of engineering students from the University of Waikato.
COMMENTARY 13
November 2014 www.engineeringnews.co.nz
‘YOUR LEADING ROTARY SCREW SPECIALIST’
YOUR ROTARY SCREW SPECIALIST
Auckland • New Plymouth • Christchurch • Timaru
Those of the 70-plus SCNZ industry mem-
bers present know of course that I refer to
the introduction of the Steel Fabricator Cer-
tification or in short, the SFC scheme. The
basic element of the SFC quality assurance
scheme is the welding fabrication quality
assurance standard ISO 3834, whose pro-
motion and introduction has been on the
HERA industry development strategy for a
long time.
However, to make it happen needed the
leadership of SCNZ manager Alistair Fussell
and a group of steel construction fabricators
responding to the challenge of much-need-
ed industry innovation, particularly
stimulated through increased threats from
fabricated steel imports to cover capacity
demands from the Christchurch re-build.
Company leadership was required on two
fronts. Firstly at the industry sector front,
the commitment to set up the scheme and
be part of the scheme governance was
required. In this role, the industry group in-
volved wanted to go further than just the
ISO3834-governed welding fabrication area.
It also wanted to cover additional functions
specific to NZ steel fabrication and its stand-
ards framework representing an important
extension into the New Zealand specific SFC
scheme.
On the second and more important leader-
ship front, it was the requirement to drive
company internal processes. Based on the
scheme’s fundamental principle to ensure
that there are appropriately qualified people
in place to run the welding fabrication
and the quality assurance process, training
people was therefore a fundamental re-
quirement for the companies to complete
before they were able to meet the scheme
requirements.
And seeing so many individuals going
through the associated HERA courses and
achieve the required qualifications is a fan-
tastic outcome, and I specifically want to
commend the individuals achieving this and
the companies supporting them.
In this context, it is worth noting that the
individuals and their functions in the scheme
are listed on one of the certificates handed
over to demonstrate compliance. Therefore,
the so named Responsible Welding Co-co-
ordinator is left in no doubt that he/she is
ultimately responsible for the delivered qual-
ity. A task they will be handling with pride,
having been equipped with the tools and
processes to manage these tasks as part of
the training and scheme implementation.
At the presentation ceremony, it was heart-
ening to see entire welding fabrication
teams walk to the front to receive their
certificates from MBIE chief executive David
Smol and HERA Welding Centre general
manager Dr Michail Karpenko, in recogni-
tion for what those teams have achieved in
a very short time.
And in the ensuing discussions with the
bosses, hearing their feedback on the com-
pany’s performance improvement following
the SFC scheme introduction gives me con-
fidence that scheme participation will only
grow across all players of the sector.
Ultimately, the benefits will accrue to
everyone on the supply and end-user side
ensuring a sustainable steel industry based
on the principles of delivering quality, value
and certainty through innovation.
Dr Wolfgang Scholz is the director
of Heavy Engineering Research
Association (HERA).
Presentation of the first eight SFC certificates to CEOs. Back row, Murray Scaife (Whakatiki Engineering), Malcolm Hammond (MJH Engineering), Greg Jensen (Jensen Steel Fabricators), Bob Hawley (Red Steel) and Bruce Mellsop (Eastbridge). Front, Wayne Carson (D & H Steel Construction), Frank van Schaijik (John Jones Steel) and Chris Chapman (Chapman Engineering)
Steel fabrication industry meets its most significant challenge By Dr Wolfgang Scholz
At its AGM last month in Hamilton, Steel Construction New Zealand (SCNZ) members used the opportunity to celebrate the introduction of the most visible industry transformation process in its sector’s history. Being intimately involved in its development, it gives me great satisfaction to see its introduction happen with such great industry commitment and industry leadership.
www.engineeringnews.co.nz November 2014
14 CASE STUDY
A machinery operator and product designer,
Mr Slee was frustrated with grease nipples
leaking, wearing and jamming. Sometimes
a traditional grease nipple would leak if
it had been scratched or worn from the
teeth inside the coupler. To make matters
worse, the coupler could also become worn,
making it difficult to know whether the
grease coupler or grease nipple was faulty.
“Often a machine operator wouldn’t have
time to replace a worn grease nipple or
grease coupler,” Mr Slee says. “This results
in grease leaking out, leaving a mechan-
ical joint or pin dry. This joint would then
wear out costing big money to refurbish or
replace.”
Mr Slee thought there must be a better way
– a grease fitting system that didn’t wear,
leak or jam would be ideal. However, all
of the systems he considered used locking
mechanisms which tended to jam under
pressure, a situation that was unacceptable.
“It wasn’t until the year 2000 when I was
doing some service work on an agricultur-
al spraying unit that I noticed a cir clip was
missing from an input hydraulic gland on a
hose reel. I was amazed that this hose reel
gland would still operate with no cir clip at
300 psi.
“But would it operate at 10,000 psi with no
cir clip? I went about testing this, discover-
ing that the hydraulic gland on the hose reel
was operating at equal pressure and with
modifications would easily handle 10,000
psi.”
14 years and 500 prototypes later Bradley
has patented/designed a superior grease
coupler and grease nipple that won’t leak,
wear or jam. The grease coupler has a
10-year guarantee and has no internal or
external parts, making it ultra-reliable com-
pared to traditional grease couplers that
have on average 10 parts. The grease nipple
has a 10-year guarantee and an optional sil-
icon dust cap is available.
Here are the top three technical challenges
Mr Slee encountered in those 14 years, in
his own words:
Designing a grease coupler with no
moving parts
“Grease flow channels were needed inside
the coupler. Traditional CNC lathes gen-
erally only drill holes at 90 degrees. This
meant the port holes needed to be capped
by laser welding, but upon further investi-
gation I found a CNC machinist who did
angle drilling. This allowed for the coupler
to be manufactured 99 percent on the CNC
lathe with no welds or joints and no inter-
nal or external parts. All that is required
after machining is chrome plating and laser
branding.”
O-ring seatings
“There is a lot to know about it. My first
seatings were totally incorrect. The O-ring
squeeze was too little or too much. Then the
O-ring groove was too wide or too narrow.
I learnt that rubber is like liquid – it can't
be compressed, it only changes shape. For
example, if the cross section drawing of an
O-ring is viewed, you will see the circular
shape become an oval with zero compres-
sion of the rubber.”
Hydraulic one-way valves
“I wanted no mechanical parts inside the
grease nipple. I designed a special flat
O-ring that I managed to get working at low
pressures. But it was unreliable at extreme
pressures of 10,000 psi. I was forced to go
with a traditional ball valve. I had trouble
with the ball seating also, it would not seal
properly onto a 118 degree face until I used
a ball nose drill. This created a nice concave
for the ball to seat into.”
For more information:
Mobile: 027 600 5555
Email: [email protected]
Website: www.nevaleak.com
2000: First prototype made in Mr Slee’s workshop using some
hand-cut rubber washers as seals to see if equal hy-
draulic pressure would work, and it did. The seals were
on the inside of the coupler. He would get help from
manual lathe machinists for the following prototypes
2001: Tolerances too sloppy between coupler and grease
nipple. O-rings can escape out off gap
2002: Incorrect squeeze ratio for O-rings. Research of O-ring
squeeze charts fixes the problem
2003: Not enough room in O-ring grooves to allow ovaling
of the O-rings. As a result the O-rings got chopped
2004: Manual lathe engineers struggle with internal machin-
ing of the grooves for the grease coupler
2008: decision to drastically reduce nipple size to 6mm.
Access to CAD drawing software. Too much difficulty
in drilling angle holes manually in couplers
How Nevaleak created the grease coupler and nipple that won’t leak, wear or jamBradley Slee caught on a product idea, and worked on it for 14 years until he got the design right. 500 prototypes later, he has patented a superior grease coupler and grease nipple that won’t leak, wear or jam. NZEN editor Romy Udanga spoke with Mr Slee on some the technical challenges he encountered along the way.
2009: Plastic back valves in grease nipple too weak for 10,000 psi
2011: Access to engineers with CNC
lathes. Slots used for intakes on
grease nipple but proved too
slow for economic manufacture.
Traditional ball valve designed for
grease nipple
2012: Laser welding used on coupler
port holes
2013: Drastic decision to swap the
O-rings from the coupler to
the grease nipple. Decision to
use standard 4mm O-rings. Decision to go with stainless
steel grease fittings to avoid tolerance problems when
electroplating
2014: A solid state coupler achieved with no welds and no moving
parts by using a CNC lathe with an angle drilling head.
Bradley Slee installing a Nevaleak grease nipple Comparison of traditional and Nevaleak grease fittings and grease couplers
Timeline notes: 500 fails, 500 learnings
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www.engineeringnews.co.nz November 2014
16 AUTOMATION
0800 55 77 33 | [email protected] | www.aurora-nz.comCall us and experienCe our quality serviCe today.
palletising, AURORA CAN HANDLE ITWith over 10,000 Robotic Palletisers installed worldwide Fuji is unmatched
in palletising technology. Experience, focus and dedication to the industry
have enabled Fuji to provide the best solution to your palletising needs.
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> High speed palletising & energy savings acheived simultaneously
> Up to 1800 cycles per hour
> Pallet Dispenser, pallet wrapper and transfer accumulation options
Fuji-Ace has been developing, supplying
and improving palletising technology for
nearly 40 years. In 1982 Fuji recognised the
changing market and met the demands of
the palletising industry by developing the
first Robotic Palletiser. It has since perfect-
ed the mechanical and electrical aspects of
robotic operation to match the needs of vir-
tually every palletising application currently
available, with over 10,000 installations in
operation.
Aurora has for many years provided superior
machinery for the bulk materials handling
industry and as solution provider, is able to
combine modular type equipment for ma-
terials handling plants large and small. The
addition of the Fuji range of Robotic Palletis-
ers means Aurora offers its clients the choice
of a high capacity, economical solution to
handling bags and boxes on their packaging
lines.
As a specifically designed palletising robot,
the Fuji-Ace system provides many benefits
over conventional robotic arm alternatives.
The Fuji-Ace palletiser reduces space and
power requirements, provides the highest
capacity cycle available, and is easily pro-
grammed and adjusted from the specific
palletising controller, removing the previ-
ously time consuming task of programming
the robot. Up to 30 stacking patterns can
be programmed into the robot’s memory.
Fuji also utilises a point-to-point control
system that further reduces and simplifies
programming time, with only the pick and
drop points needing to be programmed for
the first two layers.
Aurora provides full automation and pallet
transfer systems, specified to suit what-
ever application within all production
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At Aurora we stand close behind our prod-
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High-capacity, easy palletising with Fuji RoboticsAurora is excited to announce the addition of the Fuji range of robotic palletising systems to its extensive range of process equipment on offer.
With more than 15 years of experience in
condition monitoring, NI developed NI In-
sightCM Enterprise as its first end-to-end
software solution that addresses Big Analog
Data challenges and builds on the industrial
Internet of Things.
Using NI InsightCM Enterprise, companies
can cost-effectively monitor both critical
and ancillary rotating machinery, which
helps them gain a more holistic view of their
fleets and manage operational risk while
maintaining profitability and production
efficiency. The enterprise solution solves
the data management, data analysis and
systems management challenges that are
common in Big Analog Data applications.
Its inherent flexibility and open architecture
make it an ideal choice for meeting evolving
diagnostic program requirements.
NI InsightCM Enterprise acquires and anal-
yses sensory information, generates alarms
and allows maintenance specialists to
remotely diagnose machine faults. Ready-
to-run condition monitoring systems based
on the CompactRIO hardware platform can
acquire data from a wide range of sensors
for improved fault diagnoses. This hard-
ware and software solution simplifies the
configuration of and measurements from
thousands of sensors, so users can remotely
monitor device health, configure channels
and upgrade firmware on deployed systems.
This online condition monitoring solution is
ideal for companies in a variety of industries,
including oil and gas, power generation,
mining, rail and industrial manufacturing,
that need to optimise machine performance,
maximise uptime, reduce maintenance costs
and increase safety.
Among its benefits are:
• Cost-effective: Lowers the instrumentation
cost for monitoring both critical and other
plant equipment at a fleet-wide scale
• Open: Offers open software architecture
to access data and gain interoperability
with third-party enterprise software pack-
ages, such as CMMSs, database historians
and prognostics tools
• Easily scalable: Scales from one to
hundreds of nodes per NI InsightCM En-
terprise server and replicates one solution
at multiple facilities
• Flexible: Incorporates CompactRIO to
adapt to changing sensory needs while
maintaining the user’s investment in the
platform.
Online condition monitoring solution addresses Big Analog Data challengesNational Instruments (NI) has launched NI InsightCM Enterprise, a new software solution that helps companies gain insight into the health of their capital equipment for machine maintenance and operations.
NI developed NI InsightCM Enterprise as its first end-to-end software solution that address-es Big Analog Data challenges and builds on the industrial Internet of Things
AUTOMATION 17
November 2014 www.engineeringnews.co.nz
Globally, Fonterra produces over 22 billion
liters of milk each year. This requires only the
best resources to ensure high quality milk
is produced in ways that add real value to
Fonterra’s customers and consumers around
the world. The facility in Auckland produces
a number of products including fresh milk,
ultra high temperature (UHT) milk and cul-
tured dairy food for some of New Zealand’s
best-loved brands. The resources needed to
produce these products not only derive from
New Zealand’s natural environment, but also
the equipment used at Fonterra’s Takanini
facility.
More than 90 percent of UHT milk and
cream produced at this facility is exported
to markets in the Pacific and Asia region,
including China, Singapore and the Phil-
ippines. Due to expansion and upgrade in
order to help meet the significant growth
occurring in the global market, the UHT pro-
cessing and packaging facility now draws
between 30 to 40 megawatts of power. This
is mainly drawn by the large AC drives and
motors used in the facility’s production lines,
which package more than 750,000 liters of
fresh milk each day and can produce around
6.4 bottles per second.
Eliminating costly outages
The production lines are sensitive to voltage
sags and short term outages. These short
term outages usually range between 1 to 60
seconds, but the value of uncertain energy
caused by machinery can result in serious fi-
nancial loss. When this happens, there is no
guarantee the milk is sterilised for consumer
use, so disposal or re-processing of the milk
is required.
Fonterra New Zealand’s brand group auto-
mation and control manager Peter Williams
outlines the effect Fonterra’s power quality
events were causing: “When a glitch occurs
in our facility, we need to go through a
sterilisation process which takes around
four hours. An event like this across seven
production lines, costs us 28 hours of down-
time and around $50,000 to our business.
This would typically happen to us two, three
or four times a year.”
The PCS100 active voltage conditioner
(AVC), which is part of ABB’s power pro-
tection portfolio, is able to eliminate these
voltage disturbances in Fonterra’s facili-
ty, eliminating unwanted downtime and
wasted milk product that would ultimately
cause an on flow effect to the food and bev-
erage industry. “We would be looking to see
savings in the amount of $500,000 a year,”
Mr Williams says.
Fonterra decided to implement ABB’s
PCS100 AVC because of the global relation-
ship with ABB and reliability of its products.
“We have experience and a great deal of
faith in their products… after some due dil-
igence, we decided to implement it at our
facility,” adds Mr Williams.
Further benefits of the PCS100 AVC are the
lowest total cost of ownership by requiring
Sponsored article
ABB’s power protection technology is helping Fonterra save time and money on costly outages
Cutting costly outages for FonterraWhen leading multinational dairy manufacturer Fonterra needed a power protection solution for its processing and packaging lines at its facility in Takanini, Auckland, ABB was able to provide a solution that would eliminate voltage sags and cut out over four power quality events annually, saving an estimated cost of $500,000 per year.
no energy storage and maintaining an oper-
ating efficiency of 99 percent. With a small
design footprint, the PCS100 AVC was able
to fit into the small confined area of Fon-
terra’s equipment room, making it an ideal
solution for facilities that do not have large
amounts of space for their power protection
requirements.
Mr Williams indicates that in the future,
Fonterra plans to utilize ABB’s products to
improve the power quality in other locations
as well. “Over some time we are looking at
using this solution at other UHT sites, just to
guarantee that supply stability we need. Our
mission is to become the world’s most trust-
ed source of nutrition and ABB’s product is a
crucial part of that process,” he says.
Watch the video on YouTube at www.
youtube.com/watch?v=sU9uMLX9pI-
w&list=UU7wvKWegeU9FGzEcVhJVoDw
or contact [email protected].
com for more information.
18 SPECIAL FEATURE – ENGINEERING IN THE FOOD INDUSTRY
Waterworks Wholesale marketing commu-
nications manager Martin Thomas says the
processing plants selected the Europress
Piping System and benefited from the gen-
erous savings immediately as contractors
were able to install both hot and cold water
pipework as well as gas and chemical lines.
The metric Europress Piping System is a fast
and simple-to-assemble system for 304 and
316 stainless steel and carbon steel pipes,
and can offer piping installation savings of
up to 30 percent because of the speed at
which it can be installed.
”One contractor completed installation of
approximately 240m of 76mm Europress
pipe and fittings as well as pressure testing
equipment in just over one day. Fewer hours
on the job can result in huge savings on an
installation,” Mr Thomas says.
“The installed value is what sets the Europress
system apart. The process has been proven to
save time and money and is safe and conven-
ient. No hot work permits are needed.”
The system produces reliable joints with high
mechanical resistance and is used by the full
spectrum of industry for civil, industrial and
naval pipework system installations.
“Since its launch in 2002 in Europe, it
has revolutionised traditional installation
techniques in respect of quality and price
competitiveness,” Mr Thomas says. The
range is available in diameters ranging from
15mm to 168mm.
The Europress secret is the toroidal seat,
which when pressed seals a joint in two
stages. Mr Thomas explains: “The first radial
stage compresses the O-ring and guaran-
tees that the pipe is hermetically sealed. The
second, final stage is a geometric compres-
sion of both fitting and pipe, which creates
a mechanical joint that is resistant to both
lineal and rotational movement.
“Each joint has a highly visible press check
sleeve that allows the installer to determine
at a glance that all joints have been success-
fully crimped. Competent installers working
with the Europress range of portable 18v
hand held crimp tools can install the system
up to 10 times faster than highly specialised
welders can install systems that require con-
ventional TIG welding techniques.
“The use of original Europress fittings with
the correct pipes and approved pressing
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www.engineeringnews.co.nz November 2014
SPECIAL FEATURE – ENGINEERING IN THE FOOD INDUSTRY 19
November 2014 www.engineeringnews.co.nz
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Cedenco Foods, Gisborne-based producers
of food ingredients such as pastes, pow-
ders and purees from locally-grown fresh
fruit and vegetables, has been upgrading
their operations as part of their overall
growth strategy. With more produce pass-
ing through the facility, more overseas and
domestic sales and an anticipated 100 new
seasonal positions, Cedenco has been devel-
oping ways to work smarter. One tactic is
investing in new technology.
“Over the last few years we have introduced
bar-code scanning to help us track the bins
of produce as they move through the fa-
cility,” says Cedenco Foods information
technology manager Cleon Pinto.
“In the past we used a paper-based system
that took too much time with manual
note-taking. So we installed a limited wifi
network to support hand-held scanners.
We now attach bar-codes on each bin and
then use the scanners to track invento-
ry as the bins are shifted. We found that
this approach was faster, easier and more
accurate…so much so that we made the
strategic decision to expand wireless scan-
ning and wifi coverage across the entire
complex.”
Significant expansion
Cedenco has been on an aggressive growth
path. One initiative has been the construc-
tion of a new 3000 sq m processing factory,
including frozen goods storage, next to their
existing facility. “As we were expanding
scanning and wifi capabilities here,” con-
tinues Mr Pinto, “we looked at options to
include the new factory in our wifi coverage.
We were especially interested in finding an
AP that we could use in the cold storage…it
operates at -18 degrees C…as cold storage
is a key part of the business.”
Cedenco Foods and the team at Fujitsu’s
Gisborne office have been working togeth-
er on ICT projects since the early 2000s and
have enjoyed a ‘trusted partner’ relation-
ship. “Cedenco asked us to submit a bid to
expand wifi coverage at their current facility
with the idea to extend it to the new facto-
ry when they were ready,” says Fujitsu New
Zealand network support specialist Andy
Memmott.
“We had already installed a Fortinet Forti-
Gate 110C UTM Appliance that they used
primarily as a firewall and to provide net-
work security. Their current wifi gear was
not designed for industrial applications so
they were open to suggestions.”
“One of the features of the FortiGate
110C is the wireless controller,” notes Mr
Memmott, “so they already had all of the
management and monitoring capabilities
in place to control more than enough For-
tiAPs to cover the entire footprint of both
factories. So it was the logical decision to
recommend that Cedenco standardise their
AP constellation with Fortinet equipment.”
“We did a thorough site survey and identi-
fied a series of locations that would provide
the widest coverage with the fewest APs,”
he continues. “We took advantage of the
FortiAP’s dual-2.4/5GHz capabilities to
provide enhanced coverage as well as PoE
(power over Ethernet) to facilitate installa-
tion. We were able to give them the initial
coverage they wanted by proposing three
pole-mounted outdoor-certified FortiAP
222Bs. And since their FortiGate Appliance
was already installed, the total cost was
quite affordable. Plus the 222Bs are rated to
-25 degrees C,” he says.
“We wanted wider coverage, trouble-free
operations and affordability,” Mr Pinto says.
“In addition, we had existing infrastructure,
including a FortiGate 110C UTM Appli-
ance, that we wanted to leverage. When
we looked at all of the options, Fujitsu’s
recommendation that we standardise with
Fortinet access points was the most advan-
tageous choice.”
Fast installation, robust operations
Cedenco’s own internal technical team
carried out the actual installation with Fu-
jitsu providing configuration and support
services. “The install went very well at our
facility at the time,” says Mr Pinto. “That
was about a year ago. Everything worked as
specified. And as the new facility was being
built, we installed additional APs to cover
that area as well. The new facility opened in
February 2014. It’s interesting to note that
we did install one AP in the cold storage
room and it is operating without a hitch. So
now we have coverage over most of the two
facilities and it has provided a backbone for
scanning which has in turn allowed us to
process more food in less time.”
As Cedenco moves forward with other in-
itiatives, it will take further advantage of
its wifi network. “We plan on using wifi to
enable managers to roam throughout the
facility with their laptops, but that will come
later,” Mr Pinto concludes.
Cedenco Foods selects Fortinet Access Points for major expansionTo provide wifi coverage in their new NZ$6 million produce processing facility and increase signal strength within their existing adjacent factory, Cedenco Foods selected an array of Fortinet FortiAP 222B Access Points.
Total wifi coverage made hand-held scanners more effective tools at Cedenco Foods
www.engineeringnews.co.nz November 2014
20 SPECIAL FEATURE – WOMEN IN ENGINEERING
While 2013 census data shows 13 percent of
engineers in New Zealand are women now-
adays, figures from universities and technical
institutes show that will change dramatically
soon. The University of Auckland’s School
of Engineering had a 2013 Level 1 intake of
25 percent female students; New Zealand’s
national average was 23 percent. On top
of that, 13 percent of learners completing
Levels 5 to 7 diplomas in engineering and
related technologies were women, as were
30 percent of learners completing similar
Level 4 certificates.
Ms Smith, a civil engineer with HEB, says
when she started out she faced “road
blocks” but had no one in a similar position
to talk to about it. With the birth of her
first child in 1999, she was forced to move
into consultancy because the contractor she
worked for wouldn’t offer part-time work.
“At the time they were closed to the idea.
If someone had been there to show me the
way I could have had wider options. I’ve
worked for three different companies over
eight years, all part-time, and I’ve found the
larger ones definitely see it as something
they can offer. With the current skill short-
age, organisations understand they need
to do what they can to hold onto key em-
ployees. And if women find their employer
doesn’t offer this – look for someone who
does!”
Ms Sinclair, chief engineer at Auckland
Council’s Infrastructure and Environmental
Services, is mum to a teenage daughter
and has always worked full time. As a new
parent she was very lucky to work for a
company who had an uncommonly high
percentage of female engineers. “Even back
in the day” they automatically provided lap-
tops to mums. They understood the value of
employees, she says.
“But you have to choose the right employer
and before you do that you need to work
out how you want to be a parent. It’s a two-
way street. Once you’re clear on this you can
find an employer to work with it.”
Ms Eldridge, a full-time working mum with
two young boys is head of Waste and Indus-
try at the employee-owned Tonkin & Taylor.
She suggests thinking twice about working
full-time if the main reason you’re doing it is
for another full-time salary, as you typically
spend “a great deal on the children to make
sure they are happy and well cared for”. She
says that her company provides laptops for
home use and other flexible options for par-
ents who need it.
So far, female engineering students haven’t
been formally introduced to the issue; while
studying engineering they have no support
problems at all, but once in the workplace,
some women feel isolated. This is where
Women in Engineering (WIE) networks have
begun to do a lot of work. The University of
Auckland and University of Canterbury both
have them and the Institute of Professional
Engineers New Zealand collaborates with
them.
Dedicated WIE advisors recruits girls into
the courses, offer support if they want it,
and build strong links with schools, forming
bonds with industry and companies so that
Dr Wicaksana’s background in membrane
technology, in particular membrane fouling
propensities, gives her expertise that has
applications within many of New Zealand’s
key export markets – she is currently focus-
ing on applications of membrane processes
for the food industry, and is already work-
ing with a New Zealand dairy company on a
project related to membrane fouling control
strategies.
“It’s exciting as an engineer to be able to
apply your research to real situations,” says
Dr Wicaksana, whose PhD, undertaken at
the University of New South Wales, gave her
the tools to explore not just membrane tech-
nology for its own sake, but the potential
and actual applications of membrane tech
nology for industry – in particular food pro-
cessing and wastewater management. Dr
Wicaksana enjoys being able to contribute
to New Zealand via her work – “food pro-
duction is very important to New Zealand
– this motivates me to apply my research
to the dairy industry and the food industry
in general.”
But she’s not content with just working on
individual projects related to membrane
technology in food production applica-
tions – Dr Wicaksana would like to develop,
over time, a membrane technology re-
search group at the University of Auckland,
closely linked with industry, and that can
address real and critical industry need in
New Zealand. A research network that in-
cludes industry partners would enable her,
with colleagues, to undertake great, indus-
try-based research that answers industry
problems.
Engineering yields to family needs By Sally Webster
When engineers Nicky Smith, Sarah Sinclair and Simonne Eldridge got up to talk about balancing engineering and raising children at the University of Auckland’s School of Engineering in September, it highlighted a steadily changing gender balance and warned employers to start thinking about family-friendly policies.
Making advances in membrane technologyDr Filicia Wicaksana, who arrived in New Zealand in 2013 as a lecturer with the University of Auckland’s Chemical and Mechanical Engineering Department, is excited by the prospect of developing a research programme that has direct and tangible benefits for New Zealand industry.
Nancy Chow
Dr Filicia Wicaksana
SPECIAL FEATURE – WOMEN IN ENGINEERING 21
November 2014 www.engineeringnews.co.nz
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girls can talk to women already out there in
engineering.
The filter-through effect of more women
studying engineering is that female IPENZ
memberships have grown considerably.
Records show that in 1983, numbering 37,
women didn’t even make up 1 percent of
their members. Now they number close to
2000.
But not everyone makes it to IPENZ or ter-
tiary level meet ups. Somewhat of a poster
girl for tech level engineering certificates is
K Z Marine’s CNC operator Nancy Chow.
She would have been on the shop floor with
three other CNC guys when the Engineering
School meeting took place, putting the tool
making and machinist qualification in Stain-
less Machining she gained from Manukau
Institute of Technology to good use.
A mum of two, Ms Chow was the only
woman on the course that she took over
several years, mixing it with an apprentice-
ship and taking time out this year to have
her second child. Now training as the only
woman on the CNC mill, Ms Chow says
she enjoys every day at her work and her
employer operates a very family-friendly
business.
“Every day is a learning curve for me and it is
certainly never boring. As a mum, I’m lucky
to have a boss who knows the importance
of family. He knows that even for the men
working in the small business environment
Continued on page 22
Maire Lenihan and Suzanne Naylor
Nicky Smith
www.engineeringnews.co.nz November 2014
22 SPECIAL FEATURE – WOMEN IN ENGINEERING
Coronary artery disease is the most common
killer in the Western world, Ms Beier says.
“One in four people will die from a blockage
in one of the coronary arteries, preventing
supply of blood and oxygen to the heart.”
A common treatment for narrowed arter-
ies is ‘Percutaneous Coronary Intervention’
(PCI), where a wire mesh tube, or stent,
is inserted into the narrowed vessel and
expanded to hold it open. This is a highly
effective and low-risk treatment, is relatively
non-invasive and enables rapid improvement
in the patient’s condition.
Unfortunately, stents fail in more than 25
percent of patients, when the previous nar-
rowing reoccurs with the stent.
New stents that release medication (known
as ‘drug-eluting’ stents) promised a solution
to this problem, with the slow local release
of drugs suppressing the regrowth of the
tissue responsible for re-narrowing. A short-
term improvement is achieved, but late
failure rates increased significantly, which
carry the risk of causing sudden death.
It is known that the presence of the stent
changes blood flow, which in turn alters the
growth of tissue, and thereby affects treat-
ment outcome. Currently, there are more
than 250 different stent designs available,
each of which has a different effect on the
3D blood flow pattern.
The stent design is therefore critically im-
portant in determining treatment success or
failure. Clinical trials with groups of patients
have been unable to define the stent design
features determining success or failure due
to the complexity of the problem. More
detailed quantitative analysis is needed to
answer the question of how different stent
designs affect the complex blood flow in the
coronary arteries.
“My research aims to study the link between
Engineering stents to improve treatment of heart disease
Susann Beier
Auckland University PhD Candidate Susann Beier is working on a different aspect of engineering design. She studies blood flow in the coronary arteries and designs stents to help patients with heart disease.
stent design features, the changes in blood
flow (haemodynamics) they cause, and
impact on treatment outcome,” Ms Beier
says. “Improving stent design by measuring
the impact on blood flow may significant-
ly reduce stent failures and ultimately save
lives.”
that family comes first. If my 6 month old
baby is sick, I ring up and ask for the day off
and it is never a problem. I also have flexi-
bility of when I arrive in the morning,” Ms
Chow says.
Operating in a totally different environment
are Watercare’s Wastewater senior engineer,
Maire Lenihan and Head Works manager
and mum of three, Suzanne Naylor. Water-
care employs twice the women engineers
it did in 2007 and now women make up
20 percent of the CCO’s female engineers
overall.
“I found in the early stages I had to work
so hard – more so than anyone, so that
whenever I was challenged, I could justify
my thinking,” says Ms Lenihan. She has no
plans to start a family yet and wonders if she
did so, how she would be able to work full-
time and responsibility sign off on $1million
spending decisions in anything less than
full-time hours. Ms Naylor agrees it’s tough,
saying this is why her husband decided to
be a stay-at-home dad and support her in a
promising career.
She says it took a long time to gain the
men’s trust and doubt would always set in
again once she became obviously pregnant.
“There is immediately a negative conno-
tation when you turn up to a meeting
pregnant. It was really hard at times – some
of the guys think you’ll be hormonal and dif-
ficult to deal with.”
Continued from page 21
Both women agree that you have to be
prepared to embrace a ‘going-it-alone ap-
proach.’ To avoid other women having that
experience Naylor is starting a dedicated
young professional group within the New
Zealand Society of Large Dams. She also
mentors six young IPENZ members and as
a newcomer to the CCO, set about form-
ing the Watercare Graduate Group. The
achievement saw her win it’s Young Profes-
sional of the Year award in 2010.
Sarah Sinclair
Simonne Eldridge
WORKSHOP 23
November 2014 www.engineeringnews.co.nz
In times of ever-shorter product life cycles
and increasingly more complex and more
individualised components, generative man-
ufacturing processes can help companies
produce new and innovative products more
quickly. The unique technology combination
of laser deposition welding by means of a
powder nozzle and milling gives the user
completely new application and geometry
options. With the LASERTEC 65 3D DMG
MORI now offers a hybrid solution for com-
bined laser deposition welding and 5-axis
milling.
The market for additive processes has
grown rapidly in the past. However, up to
now these processes have been restricted
to the production of prototypes and small
parts, which could not have been manufac-
tured using conventional methods. With the
combination of the two processes, metal
deposition and metal removal, on one ma-
chine additive technology complements and
enhances traditional machining methods.
To enable generative manufacturing, the LA-
SERTEC 65 3D is equipped with a 2kW diode
laser for laser deposition welding, while
the fully fledged 5-axis milling machine in
robust monoBLOCK® design also makes it
possible to carry out highly accurate milling
operations.
Among the highlights of LASERTEC 65 3D’s
features are:
• Intelligent combination of laser deposi-
tion and milling enables maximum surface
finish and component precision
• Laser deposition welding with powder
nozzle: up to 10 x faster than powder bed
processes
• Feasibility of complete 3D components
with diameters up to 500 mm without
any supporting geometry, even with over-
hanging contours
• Direct machining of areas that are no
longer accessible on the finished part.
Producing large parts generatively
In contrast to laser melting in a powder bed,
laser deposition welding enables large parts
to be manufactured using a metal powder
nozzle. With a deposition rate of up to 1
kg/h, this process is up to 10 times faster
than the laser generation of parts in a
powder bed.
The hybrid machine combines the advan-
tages of milling, such as high precision and
surface quality, with the flexibility and high
deposition rate of powder deposition weld-
ing. “In the case of integral components,
where today 95 percent of the material is
removed by milling, with additive processes,
material is only built up where it is needed.
This leads to significant savings in raw ma-
terials and costs,” explains Sauer Lasertec
sales director Friedemann Lell.
The laser, complete with powder deposi-
tion head, is fitted into the HSK toolholder
of the milling spindle. It can be automati-
cally parked in a secure docking station
while milling operations are being carried
out on the machine. The machine and pro-
cess are operated and controlled by means
of the new 21.5” ERGOline® control with
CELOS and Operate 4.5 on Siemens 840D
solutionline.
Production of 3D contours
Using a laser diode, the metal powder is de-
posited in layers onto a base material and
fuses with this without pores or cracks. The
metal powder forms a high-strength welded
bond with the surface. A coaxial inert gas
prevents oxidation during the build-up
process.
One strength of this process is the option
of successively building up layers of different
materials. Wall thicknesses of 0.1 mm to 5
mm are possible depending on the laser and
the nozzle geometry. Even complex 3D con-
tours can be generated with any supporting
geometry.
The individual layers can then be accurately
machined before the areas become inacces-
sible to a cutter or other tools due to the
component geometry. The combination of
the two processes is a sensible choice for
repair work and the production of tools and
moulds. However, it also offers many inter-
esting options for lightweight components,
prototypes or small series production – par-
ticularly in the large-part manufacturing
sector where other additive manufacturing
processes cannot be used due to limited
space.
Economical solution
Large machines, such as those used for ma-
chining bulky components in the energy or
aerospace industries, tend to be expensive.
So the possibility of carrying out roughing,
deposition and finishing on a single machine
therefore represents a financially advanta-
geous solution for the customer. Another
example here is the energy and oil industry
where components often have to be coated
with corrosion-resistant alloys to protect
them against wear. Deposition welding pro-
vides protection for products such as pipes,
fittings, flanges and special constructions
that are used in aggressive environments.
With a hybrid solution, machining of the
base material, coating and finishing can be
carried out on one machine. This results in
cost savings and a reduction in throughput
times.
For more information:
Visit: www.dmgmori.com
Left: Generative manufacturing on LASERTEC 65 3DAbove: The DMG MORI LASERTEC 65 3D
Generative manufacture of 3D components in finished part qualityDMG MORI’s LASERTEC 65 3D, a hybrid machine that is currently unique on the market, incorporates generative laser deposition welding into a fully-fledged 5-axis milling machine.
Sponsored article
www.engineeringnews.co.nz November 2014
24 DESIGN
“We’re delighted at winning three ac-
colades,” says Gallagher Security chief
technology officer Steve Bell. “The Gal-
lagher T20 Terminal has a highly innovative
design, utilising advanced over-moulding
techniques to deliver a very robust, envi-
ronmentally protected device, designed
to complement both internal and external
decor. The T20 is a product we’re ex-
tremely proud of, and for our team, this
recognition is well deserved.”
The T20 front fascia incorporates a per-
fectly flush lens for protection of the LCD
screen behind it. The lens is created by
over-moulding clear polycarbonate over
the top of a black or white substrate. This
method gives a deep lustre, elegant lines,
and incredible robustness due to all the
design elements being embodied in one
solid part.
Combating warp
All thermoplastics undergo a size change
as they solidify in the mould. This shrink-
age is often benign and when uniform it
is easy to compensate for it in the tool
making process. At the outset of the
design stage, it was identified that in the
unique case of the T20, something more
advanced would be required.
The clear polycarbonate over-mould is
almost entirely on one side of the sub-
strate, and ordinarily this would cause the
resultant part to warp significantly. If de-
signed in the conventional way, the parts
would have been unusable. They would
have been warped into a dish shape, and
unable to fit into the assembly and per-
form other functions.
Using Finite Element Analysis (FEA), the
degree of warp was determined for a
range of moulding conditions and mate-
rial combinations. The FEA results were
then compared with real-life parts in a
simplified ‘rapid learning cycle’ experi-
ment using prototype tooling. The theory
matched the (simplified) reality, so work
commenced in applying ‘reverse warp’ to
the T20 parts proper. The idea being that
if the parts were going to dish by a certain
amount, Gallagher R&D could design them
domed in the other direction by precisely
the same amount, such that the resultant
mouldings would end up perfectly flat.
It worked. But it is no easy thing to design
an entire product as an accurately reverse
warped version of its future self.
Producing the injection mould tooling was
no picnic either. The tool cavities for both
substrate and over-mould tools have no
straight lines, no flat surfaces, and no truly
circular holes. An extremely high quality
surface finish was also required.
Combating substrate erosion
Conventional over-moulding usually
employs a relatively soft, relatively low
melting temperature over-mould com-
pared to the substrate, so that it does not
erode the underlying material during the
injection phase of the cycle.
The T20 front fascia in contrast uses poly-
carbonate as the over-mould, which is a
rigid material injected at the fairly high
temperature of 300 degrees C. The sub-
strate material is a coloured version of the
exact same material, which gives insepa-
rable bonding of the two layers as they
literally melt into one another.
A little melting is good, but too much
leads quickly to the phenomenon known
as substrate erosion. This is where the
over-mould gouges away the substrate
as it flows across it, around it, and in sev-
eral deliberate places on the T20 fascia,
through it.
Again, Gallagher R&D were able to predict
this in advance with FEA, and make the
necessary geometry adjustments so that
the issue was resolved before any waste
was incurred.
Gallagher’s security solutions are regularly
recognised for quality and innovation in
awards across the world. The Gallagher
T20 Terminal was released to the global
security market in July 2013.
The Gallagher T20 Terminal
Some design challenges in the award-winning Gallagher T20 TerminalThe Gallagher T20 Terminal, an intelligent card and PIN access control device, was awarded Gold for Tool Making, Gold for Co-Moulded Injection Moulding, and Silver in the Industrial Product categories of The New Zealand Plastics Industry 2014 Design Awards held in October 2014. NZEN editor Romy Udanga looks at some of the design features of the product.
Have a story to tell?
Contact the editor on 027 559 5771
Automation • Design • Power Systems • Machinery • Materials • Environment • Workshop • Management September 2014 VOL 45 NO. 8 Price $9
Cloud manufacturing favours NZ’s SMEs page 36
Coatings and Corrosion event a success page 32
Gough Engineering invests to increase capacity page 20
How Rocket Lab shrunk the space launch vehicle
page 12
www.totaloilsolutions.co.nz
0800 TOTAL OIL (868 256)
Contact Keith Falloon on 0800 503 305 or Jenny Pretorius on 027 559 5771
www.engineeringnews.co.nz November 2014
26 MATERIALS
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We cut to size!
Process attributes
Below are the attributes of a cutting pro-
cess that are most often important from a
metal fabricator or job shop perspective
and a brief description of each process.
Go online at http://www.engineeringnews.
co.nz/content/determining-the-best-pro-
cess-for-metal-cutting/ to see the detailed
attributes of these processes, including
a comparative ‘complete system’ capital
equipment cost.
• Capital equipment cost
While each of these cutting processes re-
quires relatively sophisticated CNC motion
control and fume control equipment as
well as CAD and CAM software packages
to unlock the best potential, there are dif-
ferences in these requirements for each
process. As an example, motion control sys-
tems on a laser designed to cut thin steel at
very high speeds are required to have much
greater accuracy compared to the motion
control system for waterjet or oxy-fuel that
operates at much lower cutting speeds.
These requirements have a direct and often
large effect on capital equipment cost differ-
ences between these technologies.
• Cutting cost per part or per metre
This type of cost calculation must include
consumables (gas usage, consumable noz-
zles, electrodes, garnet abrasive, etc.) and
utilities, (electricity, water, etc.) In some
cases, amortised capital equipment cost
may also be included, as well as labour cost
(such as for loading fresh sheets, or unload-
ing cut parts and scrap). It is necessary to
ensure that the same type of inputs is used
for each system when comparing the rel-
ative cutting costs of each. The cut costs
should be broken down to per metre or per
part as opposed to cutting cost per hour, as
this levels out the speed advantages that
some processes have on some materials.
The cutting cost-per-metre calculations will
always show large advantages to the pro-
cesses with the cut speed advantage.
• Ease of use
This attribute puts the heaviest weight on
the software (especially CAM) as well as the
CNC control capability. Today’s best technol-
ogy systems have relatively short learning
curves and have developed embedded ex-
pertise in the systems, often minimizing the
need for expert operators. While difficult to
put a value on these types of advantages,
it is necessary to think about this when in-
troducing sophisticated systems on the shop
floor.
• Productivity
Often also called throughput, this is essen-
tially the number of parts that have been cut
to specification at the end of a shift. Produc-
tivity or cut speed is the biggest influence on
the real cost per part and, in some cases, ac-
curacy specifications of cut parts (that may
have been tighter than necessary) can be
reduced in favour of a process that provides
dramatically lower cut costs and a bigger
pile of parts in a shorter period of time.
• Cut part accuracy
There are many ways to measure the accu-
racy of the wide variety of parts produced
in metal fabricating. Often the outside
contours of parts have much looser toler-
ances as compared to inside details such as
holes. Also, often times, only the top of a
part is measured, yet the bottom (based on
edge taper) will be substantially different in
dimension. For simplicity, plus or minus ex-
pectations for tolerance as measured from
the top of the part will be used here, as well
as a reference to edge angularity for each of
the processes.
• Edge quality and metallurgical effects
All of these processes will produce some
different effects on the cut edge metallur-
gy that can affect machinability, formability
and weldability.
• Service and maintenance requirements
Some of the long-term operating cost calcu-
lations with each form of these systems will
be affected by the need for maintenance,
as well as the level of expertise required to
perform that maintenance.
Oxy-fuel
The oxy-fuel cutting process is by far the
simplest of the cutting technologies being
discussed. The process essentially uses a fuel
gas to heat steel to its ‘kindling’ temperature
of around 980 degrees C. Once the steel is
at this temperature (preheat), a pure oxygen
jet is activated to create an exothermic re-
action with the hot steel, rapidly eroding
the steel. Oxy-fuel has the ability to cut
only mild steel, and does a good job in the
thickness range 6 -150 mm. Cutting speeds
are better than other processes on materi-
al thicknesses over about 50 mm. It is easy
and inexpensive to add multiple torches to a
CNC machine to increase cutting speeds by
cutting multiple parts simultaneously.
High-definition plasma
High definition plasma uses a high temper-
ature ionised gas to produce a high energy
density cutting arc that is capable of cutting
any conductive material. The latest tech-
nology systems can be almost completely
automated to eliminate the need for oper-
ator expertise and do their best work on 0.5
– 50 mm steel thickness with a maximum
up to 80 mm, and do well on steel and al-
uminium from 0.5 mm through to 160 mm
thickness.
Determining the best process for metal cutting: plasma, oxy-fuel, laser or abrasive waterjetHypertherm designs and produces three of the four major metal sheet and plate cutting processes used in a wide range of metal cutting applications, and is regularly asked which is the best system to use for a given application or range of products. The answer is not always simple and does not always involve just one of these processes. In reality, none of the processes are perfect in respect to their capabilities for handling all cutting requirements; rather, each has its niche area that may involve a thickness range, cut part tolerance advantage, metallurgical advantage or an outright speed/productivity advantage.
Hypertherm’s HDi thin stainless steel technology brings
HyDefinition® cutting technology to thin stainless 3
mm to 6 mm
HyPrecision waterjet cutting of aluminium gears
By Jim Colt
MATERIALS 27
November 2014 www.engineeringnews.co.nz
Total steel requirements under one roof
Call us today on 0800 478 335 Or find out more online at www.steelandtube.co.nz
Largest range of steel products Standard steel products – sheet, plate, flats, bars, rounds Tubes, pipes and RHS in a wide range of sizes Special steels – medium, high carbon and alloy steels Sheets – uncoated, hot dipped and electro galvanised Stainless steels in sheets, plates, rounds, rods and tubes Fasteners – engineers bolt, set screws, cotter pins, studbolts, threaded rods Chain & rigging for a range of applications Industrial supplies –power bits, tools, adhesives, lubricants
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Product specialistsAt all key locations to provide expert knowledge on attributes and applications
3 kW fibre laser
Fibre laser cutting systems are the latest
technology in laser cutting. These systems,
using a solid state laser generator or power
source, are far more efficient than the CO2
laser systems that they are quickly replacing
in the field.
Furthermore, fibre lasers operate at a light
wavelength that allows them to deliver
the beam to the cutting head using a flex-
ible (fiber optic) cable, as compared to the
mirror and tube delivery system used by
CO2 lasers. This provides a simpler com-
plete system layout which requires far less
maintenance as compared to the older tech-
nology. The laser uses a properly focused,
high energy laser to melt a small spot on the
material being cut, and an assist gas (typi-
cally oxygen for cutting steel) to remove the
molten metal. A 3 kW fibre laser can cut
with similar speeds and power to a 4 to 5
kW CO2 laser, indicating its better efficien-
cy. Cut capability on steel is from thin gauge
to about 20 mm.
Abrasive waterjet
Waterjet technology has been in use for
decades for cutting a wide variety of mate-
rials from cake to granite. Softer materials
can be cut with a pure high pressure wa-
terjet (2,750 – 4,135 bar) forced through
an orifice to increase its velocity and energy
density. Abrasive waterjets inject an abrasive
(usually garnet) downstream of the orifice,
so the abrasive becomes the `teeth` of the
saw, propelled by the waterjet to do the
cutting job. Today`s best technology systems
have pumps that can boost water pressure
to as much as 6,900 bar. Higher pressure
means higher cutting speeds, but this has
historically increased downtime for mainte-
nance (pump seals fail periodically and must
be replaced). The latest technology systems
have improved rebuild ability, allowing for
minimal downtime for maintenance. Huge
advantages for abrasive waterjet over other
processes are that no heat affected zone is
produced and its ability to cut almost any-
thing. In addition waterjet provides the best
tolerances. The biggest downside of wa-
terjet is that the cutting speeds are lower
compared to the other processes.
Summary
Selecting the best cutting process depends
on the specific application, the business
needs and other critical factors.
Oxy-fuel is limited to mild steel and is not
effective on stainless or aluminium. It is typ-
ically used for very thick plate.
Plasma provides an optimal mix of cut qual-
ity, productivity and operating costs for mild
steel, stainless and aluminium across a wide
range of thicknesses.
Laser provides excellent cut quality and pro-
ductivity on material less than 6 mm and can
be used up to 20 mm.
Waterjet can be used to cut a wide variety
of materials including steel, stone, granite,
food, etc. It provides the best tolerances and
there is no heat affected zone, although cut
speeds are lower.
More online: To see the detailed at-
tributes of these processes, including
a comparative ‘complete system’
capital equipment cost visit www.
engineeringnews.co.nz/content/determin-
ing-the-best-process-for-metal-cutting/.
Jim Colt is application technology
manager at Hypertherm Inc
Examples of HyDefinition plasma cut profilesHyDefinition plasma bevel cutting
www.engineeringnews.co.nz November 2014
28 POWER SYSTEMS
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The plates – made of hundreds of kilos
of steel and often weighted down fur-
ther with accumulated debris buildup
on top – are traditionally loosened by
mechanics who have to crawl under-
neath giant machines to line up the
bolt holes. Deaths and scores of crush
injuries have resulted over the last 10
years.
A solution to the problem is offered by
Safety MITS’ Tracked Elevating Device,
TED, which eliminates the human
element from the critical lift stage un-
derneath equipment, by employing
remote control of the lifting device.
TEDs can travel across any terrain and
can safely lift up to 800kg. They have a
360-degree turntable at the top, which
makes lining up ball joints safer, quick-
er and easier than the conventional
methods using slings and chain block,
says Timothy Lightfoot, product devel-
opment director at Safety MITS, which
markets the product to global markets
including New Zealand.
“In addition to making belly plate removal
safer, it also makes it significantly more ef-
ficient. Safety MITS collected customer data
from Thiess, Peabody Energy and Glencore
over a one year period and found that by
using TED to remove and install belly plates
they were able to reduce work time by 73.5
percent while using one less mechanic,” he
says.
These savings don’t just apply to belly plates
either. TED can also be used for equaliser
bars, cutting edges, steer cylinders, load
rollers, sound suppression equipment,
engine sumps and many other applications.
TED is designed and manufactured to with-
stand the harsh environments that heavy
equipment works in every day around the
globe. It is built with total compliance to
Australian and New Zealand mining stand-
ards (ASNZ 4240), which are respected
globally. TED comes with a range of at-
tachments, which can be easily installed
and removed at a moment’s notice. These
include:
• The Rhino Stand Locator, which allows
users to locate stands underneath elevated
bulldozers without crawling underneath
the suspended load.
• The Cutting Edge tool, which has been
designed to assist in the safe removal and
installation of cutting edges on bulldozers,
graders scrapers and loaders.
• The Load Roller Cradle, which is de-
signed to assist in the easy removal and
installation of track roller components on
bulldozers, drills and excavators.
• The Tie Rod and Steer Cylinder Cradle, which
is designed to assist in the safe removal and
installation of steer cylinders and tie rods.
The cradle conveniently bolts to the turn-
table on top of TED allowing it to rotate
360 degrees.
For more information:
Email: [email protected]
Visit: www.safetymits.com
Tracked elevating device enhances maintenance safety while reducing downtimeRemoving belly plates from bulldozers and other tracked vehicles requiring maintenance of internal components can be fraught with extreme physical hazard, downtime and expense.
Tracked Elevating Device (TED) lifting a bulldozer equaliser bar
POWER SYSTEMS 29
November 2014 www.engineeringnews.co.nz
This was the situation for a horticultural
engineering company and an engineering
firm that acquired a new injection moulding
machine.
“The horticultural engineering company
wanted a sprayer – but not just an ordinary
sprayer,” Hyspecs sales engineer Andrew
Magon says.
“The requirements are for it to be self-pro-
pelled, the spraying unit had to fit below a
canopy, and allow an operator to sit in a re-
clined sitting position to drive it.”
Mr Magon, who loves the opportunity to
build something new, discussed the client’s
requirements with Christchurch-based Hy-
specs South Island branch manager Owen
Ladbrook.
Starting with Hyspecs in late 1998, Mr
Ladbrook holds a Bachelor in Mechanical
Engineering degree. He has experience in
production machinery design specialising
in manufacturing processes and machine
commissioning, and has particular interest
in machine controls and enjoys bringing ma-
chinery to life.
Mr Magon worked with Mr Ladbrook to
design the sprayer that their client had
thought up. The Hyspecs Service department
was then deployed to build the sprayer.
The project was successfully commissioned
by Mr Magon and the team at Hyspecs.
“It was a successful combination of the
horticultural engineering company’s brilliant
idea and expert manufacturing by the Hys-
pecs team,” Mr Magon says.
In the second case, the engineering firm that
acquired a new injection moulding machine
needed a hydraulic power pack (HPU), and
approached Hyspecs sales engineer Scott
Clemens. The company has used Hyspecs
before and knew that it could design and
build the power pack that is needed.
Mr Clemens took charge of the project with
the aim of delivering high accuracy and
quick setup times, he developed a suitable
design that uses a machine controller, HMI
touch-screen and high-performance pro-
portional valves. He then worked with the
Hyspecs Service team to build, deliver and
commission the HPU.
When you need electronically con-
trolled hydraulic driven power, call
Hyspecs to discuss your requirements on
0800 497 732.
Built from scratch
When you need a specialised piece of machinery, and can describe what you want and need it to do, but it doesn’t exist, what do you do? Hyspecs’ answer? You build it from scratch.
Owen Ladbrook, Scott Clemens and Andrew Magon
The self-propelled spraying unit being built for the horticultural engineering company in the customer’s workshop
The hydraulic power pack designed and built by Hyspecs for the plastic moulding company
Sponsored article
www.engineeringnews.co.nz November 2014
30 ENVIRONMENT
The Opus Wind Tunnel is used primarily for
environmental testing of wind flows around
buildings and new developments. It has also
been used for one-off projects such as ex-
amining the wind flow around cricket balls
for swing bowlers, testing the strength of
different umbrella designs and looking at
snow drift around buildings at Scott Base in
Antarctica.
The wind tunnel has a recirculating config-
uration with a 3m by 1.5m cross-section,
computer-controlled instrumentation and
data acquisition systems, and an extensive
reference library acquired from over 40 years
of analytical investigations, modelling and
full-scale testing.
Common wind issues resulting from new
building developments include people and
amenities being blown around at street level;
noise resulting from sharp edges, shape
geometry and the volume of spaces wind
is forced to flow through; and damage to
cladding, facades and other design features.
Such issues derive from building design and
alterations,and can be readily identified and
mitigated through testing in the Opus Wind
Tunnel.
In studies of wind flows around buildings
and new developments, for example, the
force that pedestrians feel is proportional to
the wind speed squared; so if you double the
wind speed, the force increases by a factor
of four. Increases in wind speed from an ex-
isting gust speed of 10m/s to 20m/s are not
uncommon, with one of the biggest wind
effects being an increase in gust speed from
17m/s to 35m/s.
Examples of wind tunnel investigations in-
clude the effects of strong winds around
the Novotel Auckland Airport Hotel which
were causing stoppages and performance
problems with the building’s revolving
door entry. Mitigation strategies including
changes to the existing canopy and various
combinations of vertical screens and fences
were investigated in the wind tunnel. Short
vertical screens located close to the entrance
were recommended as a result of the study.
The original design of the Majestic Centre,
Wellington was a tall, rectangular shape
with hard edges. When it was tested in the
tunnel the wind effects at ground level were
extreme and unsafe for pedestrians. Opus
Research and the designers played around
with the shape and ended up with the
round, smoother design it now is. However,
wind effects around the building’s entrance-
way were still problematic so Opus Research
designed a perforated, space-frame canopy
which effectively breaks up the wind as it
comes down the front of the building.
When the original design for Westpac Sta-
dium in Wellington was put through the
Opus Wind Tunnel there was too much wind
loading on the roof, which meant it would
have needed to be extremely strong and ex-
pensive. As a result of tunnel testing Opus
Research designed an offset leading edge to
the roof which drastically reduced wind loads
and enabled the design and build of a lower
strength/lower cost roof. They also designed
the slatted metal screens on the walkway
from the stadium to the train station which
reduces wind impact on pedestrians.
For more information:
Email: [email protected]
The wind tunnelExamining wind flows at the Opus Wind TunnelEarlier this year Opus Research relocated to new premises in Petone, Wellington, where it built a brand new boundary-layer wind tunnel – the only commercially owned and operated wind engineering facility in New Zealand.
ENVIRONMENT 31
November 2014 www.engineeringnews.co.nz
» Air Tools and accessories » Airless Accessories » Airless Sprayers » Automotive » Food
W A Strouds offers everything from Parts, Servicing Of Equipment, Repairs and advice on New Upgrading of small and large Powder Coating Systems
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www.strouds.co.nz [email protected] 09 479 8860
WA Stroud’s workshop manager, Gert Visser,
says the most notable of these is the tool’s
ability to coat complex geometries with out-
standing efficiency and quality, even in the
most challenging environment. “In the two
years WA Stroud, Gema’s sole New Zealand
agent the past decade, has been selling the
product, we’ve had excellent feedback on all
its functions, but this feature has been men-
tioned most often,” he says. He explains
how the OptiFlex 2 B works and how its fea-
tures enable it to achieve its performance.
The robust steel construction, mobile cart
unit delivers fast turnaround for small to
medium production runs, in particular when
colour change is a critical part of a company’s
powder coating operation. Designed to use
the powder manufacturer’s original carton,
an inclined vibration table that fluidizes the
powder allows complete emptying of the
powder box via the suction tube. The tube’s
improved design provides consistent powder
flow, ensuring a more stable powder cloud
and consequent smoothly uniform finish. In
addition, the suction tube’s small diameter
assists fast, thorough cleaning.
The tube transports the fluidized powder to
the die-cast zinc powder pump, which has
a new ultra-efficient 45-degrees design that
optimises air consumption from the 85psi
compressor. This results in the consistent
delivery and faster flow of even heavier
powders such as zinc undercoat or urethane
topcoat. Aiding the OptiFlex 2 B’s precision
coating abilities is another new feature –
three digital air valve controls on the pump
that ensures powder flow is constant, result-
ing in a more even, silkier coat.
Mr Visser demonstrates how the industrial
strength yet lightweight, ergonomically de-
signed gun provides good in-hand balance.
“The one piece gun body design allows un-
hindered flow of powder. In addition, the
true 100kv of first pass power in the cas-
cade efficiently charges all types of powders
and improves wrap and transfer efficiency to
among the highest in the industry.
“New-generation Gema nozzles provides
optimal powder distribution and penetra-
tion. This means more power on the work
piece, and less powder in the recovery
system,” he says.
The equipment also features PowerClean™,
a new technology that cleans the entire
powder path from the pump to the gun tip.
On-gun remote control gives the operator
the flexibility to adjust parameters without
turning away from the job and easily activate
the PowerClean mode. “Using powerful
blasts of air (30 Nm3/h), OptiFlex not only
improves performance when spraying chal-
lenging powders, but makes cleaning and
colour changes easier,” Mr Visser says.
But the feature that has users talking is the
controller, set on the industry’s first 360-de-
grees rotating control unit. It offers three
standard programs. These are flat parts,
profiles, and recoating. In addition, it has
25 other programming options through its
precision charge control (PCC) function that
allows the user to set powder output, air
volume, current and voltage, and save them
for recall at any time. “The PCC feature en-
sures not only precision control of current
and voltage that allows maximum efficiency
and uniformity of coating, but also greater
accuracy and adjustability of current settings
below 10 µA when working with challeng-
ing powders such as metallics and special
effects.
“This means the Faraday Effect and the
manual effort that goes into preventing it
is something of the past,” Mr Visser says.”
Feedback from users of this consistent seller
also indicate that the PCC current settings
help eliminate back ionisation, or cratering,
on recoats.
The optional SuperCorona® collects and
neutralizes the free ions that would disturb
powder deposition on the object in situation
of bad earthing or high humidity.
One happy OptiFlex 2 B owner, Ross Hume,
owner and manager of Osbournes Ltd in
Auckland, says he now easily achieves the
high powder coating quality he demands.
Osbournes manufactures and installs com-
mercial ventilation louvres that are mostly
coated. “We decided to put our own
powder coating plant in, as we were very
unhappy with the quality of our outsourced
powder coating service,” he recalls.
When the Osbournes team compared
the two leading powder coating equip-
ment brands, and found out that most of
the large aluminium extruders used Gema
equipment, it decided to buy the Gema
Optiflex2 B powder coating unit for three
reasons. First, the build quality of the Gema
Opitflex 2 B unit was far superior; second,
it is simple to use despite its advanced fea-
tures; and third, the expertise and support
that WA Stroud gave the team at the time
and continues to give are excellent.
“I unreservedly recommend the Gema Op-
tiflex2 B powder coating equipment to
anyone thinking of upgrading or investing
in new equipment,” Mr Hume says.
Sponsored article
The OptiFlex 2 B
OptiFlex 2 B under perfect controlThere are many reasons why the most recent model of Gema’s manual powder coating equipment range, the OptiFlex®2 B, puts the world’s “…most advanced technology” in this field in the palm of the operator’s hand.
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NEW WEBSITE!
MANAGEMENT 33
November 2014 www.engineeringnews.co.nz
Frustrated with the success ratio of the
products, Mr Schukin has developed and
launched the Innovation Deck a new set of
playing cards for engineers and inventors.
It provides an effective "brain hack" that
helps product creators to quickly refocus on
the customer and generate a wide variety
of solutions, allowing the creators to avoid
spending months on developing a solution
that has no potential.
It is frighteningly challenging to create new
inventions and products. Very few awarded
patents actually find their way to realization
in the form of new products. And that's not
all: according to the US Department of Com-
merce, for those products that get through
the hurdles of development and manufac-
turing, and are launched to the market, over
90 percent will fail in the first four years.
Why is it so difficult to create commercially
viable products? According to Mr Schukin,
our brains are to blame.
"Our brains are built up in such a way that
we delete most of the information that
comes our way," he says. "We're deletion
machines. For example, if right now you are
focused on reading an article online, you
are likely to delete most of the information
around you. You might not notice the noise
of the computer fan, or how warm your feet
may feel, until I mention it."
He says that a similar thing happens when
we develop products: once we get a prod-
uct idea that we believe in, we focus on it.
And as we put our idea into the spotlight,
we tend to delete everything else. We are
so laser-focused on developing our solution,
we ignore the inputs from the market and
whether there is a better way to add value
to the customer.
Mr Schukin mentions we should conscious-
ly look for ways to stop for a minute and
re-evaluate customers' problems and the
possible solutions available to us. "Those
who are able to control their focus, create
products that sell," he says.
After working with many small and large
businesses on product development, and
seeing people miss crucial customer inputs,
he decided to create the Innovation Deck.
These playing cards, designed for engineers
and inventors, contain a set of novel ques-
tions and techniques that allow us to easily
and quickly identify improvement opportu-
nities for a product, generate a wide range
of innovative ideas and choose an optimal
solution.
The Innovation Deck has just been launched
as a crowdfunding project on IndieGoGo
and can be downloaded at http://igg.me/at/
InnovationDeck/x/
For more information:
Contact: Andrey Schukin
Email: [email protected]
Andrey Schukin
The playing cards contain a set of novel questions and techniques for
product creators
New problem-solving cards provide a “brain hack” for product creatorsThe vast majority of new products fail. According to creativity and innovation expert Andrey Schukin, one of the main reasons is the way our brain functions: once we truly focus on developing our own product idea, it tends to delete most of the information that comes from the market.
2014
TAKING KNOWLEDGE BACKTO THE WORKPLACE!
Information, Inspiration& Interactive Displays
Get in early to reserve your placeAnd maximize your exposure...
Free public trade expo, Tuesday 11th November 2014
Kingsgate Hotel, Hamilton12th - 13th NOVEMBER
2 Day Conference $680 + gstBring a mate and it’s $440 + gst each!Exhibition space from:$800 + gstRegister Online Today: www.mesnz.org.nz/nmec
Email: [email protected]: Leanne Powley (09) 296 1333
NATIONAL MAINTENANCE ENGINEERING CONFERENCE 35
November 2014 www.engineeringnews.co.nz
As a dedicated bearing and power trans-
mission service company, Hamilton-based
Waikato Bearings’ experienced staff listen,
take a proactive approach when determin-
ing the best course of action required, solve
maintenance problems and do whatever it
takes to get plants operating again when
breakdowns occur.
As an SKF distributor, we stock all types of
rolling bearings, seals, drive belts, chains,
sprockets, couplings and lubrication sys-
tems. We will also locate components and
keep you informed at all times.
Technology enables infinite options when
developing a structured maintenance pro-
gramme. How critical a machine is in the
production cycle and cost of downtime,
determines how maintenance will be
managed.
Understanding your plant, knowing what
bearings and parts are required and wheth-
er they are readily available. If not readily
available, should there be insurance stock
on site? Waikato Bearings can help you de-
velop an asset management database.
Lubrication is often overdone or neglected,
either way a bearing’s service life is com-
promised. Centralised lubrication systems
optimise lubricant use and machine perfor-
mance. We can work with you to develop a
sustainable lubrication programme.
Vesconite unlike bronze does not require
lubrication and operates in wet and dirty en-
vironments. Water acts as lubricant allowing
wet and dirty applications to be considered.
Talk to us about Vesconite and the potential
to reduce maintenance costs.
Please feel welcome to have a conversation
about what it is worth to your company to
deal with suppliers who are passionate. It is
in our interest to look after your interests.
Waikato Bearings Ltd, an authorised SKF distributor, is proud to be part of the 2014 National Maintenance Engineers Conference.
Proactive maintenance with Waikato Bearings
www.waikatobearings.co.nz
11 Northway Street, Te Rapa, Hamilton P: 07 850 6155 | F: 07 850 6144 | E: [email protected]
“This year’s conference is a step change,”
says Maintenance Engineering Society of
New Zealand (MESNZ) secretary and NMEC
event director Craig Carlyle. “It is definitely
bigger and better than whatever we have
done since 2003. It will be a real opportuni-
ty for maintenance engineers to renew their
ties with their peers in the industry.”
Three weeks before the conference dates,
attendee registration was at an all-time
high, with the number already exceeding
200, compared to last year’s 175. Attend-
ees represent maintenance engineers from
the dairy, meat, food and beverage, forest-
ry, health, quarries/mining, wood products,
pulp and paper, textiles, agricultural, pack-
aging, engineering, site maintenance and
manufacturing industries.
“We are observing a new trend in attend-
ee registration,” Mr Carlyle says. “We are
seeing a lot more companies that we have
not heard of before. There are fresh names
and faces, and companies who used to send
one staff before are now sending more of
their people.”
Presented by the Maintenance Engineering
Society of New Zealand (MESNZ), a technical
interest group of IPENZ, this year’s confer-
ence and its associated trade expo carries
the theme ‘Lifting the game of maintenance
engineering in NZ’.
“In line with our theme, New Zealand’s en-
gineering future will be very much enhanced
by the knowledge transfer and networking
that will happen during the annual confer-
ence,” Mr Carlyle adds.
Conference attendees who have booked
the site tour will be given a first-hand look
of some of the maintenance programmes
being implemented at the Genesis Energy
Huntly Power Plant. “It is not every day
that engineers can get access to a facility
like Genesis Energy’s power plant. We are
thankful to the management of Genesis for
this opportunity they granted us,” Mr Car-
lyle says.
The exhibitor list has also grown, repre-
senting engineering supplies, careers and
employment, hydraulics, pneumatics, bear-
ings, software, preventative maintenance,
condition monitoring, electric motors and
many more. This include CRC Industries New
Zealand, EagleBurgmann, Eurotec, Filtercorp
International, Hydraulink Fluid Connectors,
James Walker NZ, K2 Technology, Klinger,
machinemonitor NZ, Mainstream Engineer-
ing, MM Kembla NZ, SEW Eurodrive, SGS
New Zealand, SKF, Thorn Lighting (NZ),
Zumtobel Group, Vitech Reliability and Wai-
kato Bearings.
Mr Carlyle says the new venue, Kingsgate
Hotel Hamilton, gives the conference a
larger exhibition and conference area.
New topics and new expert speakers are
also in the line-up. Among the timely issues
that will be on the table is the new Health
and Safety Act and the associated regula-
tions and guidelines, and how they present
the greatest change to industry and mainte-
Step change for iconic Maintenance Engineering Conference
Conference attendance in 2014 is expected to be 20 percent more than last year’s
The much anticipated National Maintenance Engineering Conference (NMEC) has “NEW AND BETTER” marked all over it. Scheduled this November 12 and 13, 2014, the event has new attendees, new exhibitors, new speakers, new topics, as well as a new venue and new people on the organising committee.
nance engineers in the last 20 years.
Other topics include discussions on the tools
and systems to better manage and maintain
assets and case studies on material failure,
plant efficiency and reliability improvement
and inspections.
The recipient of the MESNZ Bill Buckley
Scholarship award will also be announced at
the conference.
The two day conference is preceded by a
public day featuring training opportunities
and a Public Trade Expo.
Apart from the annual conference, part of
MESNZ’s upskilling programme for main-
tenance engineers is a regular network
evening hosted by prominent industrial
and manufacturing engineering companies
in the country. The latest was at the Buck-
ley Systems in Auckland in October, and
the next will be at SAFE group (Drury) in
December.
Networking is a big part of the annual National Maintenance Engineering Conference
www.engineeringnews.co.nz November 2014
36 NATIONAL MAINTENANCE ENGINEERING CONFERENCE
James Walker New Zealand Tel: 09 272 1599 Fax: 09 272 3061 Email: [email protected]
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Tel: 09 272 1599 Email: [email protected]
Mr Buckley’s award was presented on Octo-
ber 15 at a networking event hosted by his
Mt Wellington-based company Buckley Sys-
tems (BSL), which produces super magnets
for the global silicon chip industry.
The award was presented by Larry Wiechern.
Maintenance Society honours Bill BuckleyIconic Kiwi engineer Bill Buckley was made a patron of the Maintenance Engineering Society of New Zealand (MESNZ) in honour of his contribution to engineering and support for tradesmen.
From left, Glenn Pepper, Larry Wiechern, Craig Carlyle, Bill Buckley, Leanne Powley, Barry Robinson and Karolina Bratek
“Bill is an engineer that reflects the princi-
ples of the 120-plus engineers present this
evening,” he says. “He is and always has
been a strong supporter of apprentice train-
ing, and takes the time to talk and inspire
young pre-trade apprentices. He is a pretty
special engineer and this has been shown by
the wide range of awards he has received
over the years.”
Mr Buckley, a public figure recognised for
his achievements in engineering, yachting
and motorsport, has long been a strong ad-
vocate for engineering and apprentices. He
won the 2012 Ernst & Young New Zealand
Entrepreneur of the Year award and was a
finalist in the 2012 World Entrepreneur of
the Year held in Monte Carlo. His list of
awards include a recognition in the 2013
James Walker New Zealand Tel: 09 272 1599 Fax: 09 272 3061 Email: [email protected]
Eliminating shock, noise and vibration problems
•Mounting pads
•Machinery mounts
•Pipe grips
High performance vibration & noise attenuation for every application
Eliminating vibration, noise and shock problems on industrial pipe and plant
installationsMany years of involvement with the construction, onshore/offshore oil & gas, engineering and production industries have led to the development of a large range of elastomer based components that provide unique solutions for machinery mounting, building support, vibration reduction, pipe management and noise reduction.
TICO Pipe GripsDeep Water Exploration and production in hostile environments demands the highest quality equipment. That equipment is only as good as the component parts from which it is built, so when we worked with leading offshore specifiers to develop an isolated pipe hanger this philosophy was our starting point.
TICO S Machinery Mounting MaterialTICO S is a high performance machinery mounting material manufactured from a blend of carefully selected cork particles and polychloroprene / acrylonitrile elastomers. It matches today’s fast changing manufacturing environment, where ease of machine mounting and flexibility of plant layout are prime factors.
TICO High Stress MountingsTICO Hi-Duty pads and buffers take on the toughest tasks. They have the strength and resilience to cushion massive impacts, absorb fierce shock loads, and attenuate severe vibration from heavy plant.
TICO Sliding BearingsAllowable movements within a building structure can be accommodated by the range of TICO Resilient Seatings, but in some cases the movement required is much greater than those seatings are capable of accepting. TICO Sliding Bearings are the ideal answer to this problem, providing an economical load bearing sliding support with very low friction characteristics and virtually an unlimited degree of movement.
Tel: 09 272 1599 Email: [email protected]
NATIONAL MAINTENANCE ENGINEERING CONFERENCE 37
November 2014 www.engineeringnews.co.nz
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New Year Honours List when he was made
a Companion of the NZ Order of Merit for
services to technology, business and mot-
orsport, as well as being inducted into the
Hi-Tech Hall of Fame in 2013 as New Zea-
land Hi-Tech Trust’s Flying Kiwi.
He was visibly pleased to be honoured by his
peers and spoke warmly of the rich history
of New Zealand engineering companies that
had formed his career.
A group of 120 attendees were treated to
a bonnet-up look at the Buckley Systems
plant as part of the networking evening.
The experienced group were amazed at
the size and scope of the operation which
machines, fabricates and assembles high
technology magnets for export around the
world. While the machining centres were
leading edge and fully utilised, evidence of
the Kiwi can-do innovative attitude pervad-
ed the BSL facility.
BSL chief operating officer Mark Stolten
says it was a privilege to host the MESNZ
networking event. “Our staff enjoyed the
evening and it ended up a great team build-
ing exercise for us,” he says. “Thank you for
the award to Bill…as we all know he is a
great man and has put New Zealand on the
global playground of business.”
The Maintenance Engineering Society is
active across New Zealand, providing op-
portunities for maintenance engineers and
manufacturing operations to network and
share innovations and experiences; both at
a national level at their annual conference
or at these regional events.
The final network evening for 2014 is
planned for SAFE group (Drury) in December.
About 120 attendees were treated to a bonnet-up look at the Buckley Systems plant as part of the MESNZ October networking evening
Buckley Systems Ltd, the company Bill Buckley founded in 1986, is a leading manufacturer of precision electromagnets, charged particle beam line systems, and high-vacuum equipment used in the semiconductor ion implant industry, along with medical therapy systems, border security, solar industry and particle accelerators for physics research
The VANZ Annual Conference and Awareness Day is the premier networking opportunity in both New Zealand and Australia to get your maintenance front line staff motivated and up to date with World Best Maintenance Practices and Reliability Engineering Solutions.
The initial VANZ workshop and conference was held in 1989 with around 80 delegates; since then VANZ conferences have consistently attracted many hundreds of delegates from all over New Zealand, Australia and the world.
VANZ conferences have been highly successful because of the basic agenda - a friendly open forum where front line staff are encouraged to share experiences, network with other industry colleagues and evaluate vendor technologies and practices.VANZ invites a world recognized authorities in reliability engineering and maintenance practices to present informative and motivating presentations at each conference.
The conference also features a wide range of innovative papers and case studies direct from a variety of New Zealand and Australasian industries. These include Pulp & Paper, Forestry, Dairy Industry, Petrochemical, Food and Beverage, Infrastructure and Power Generation companies.
We need your papers now.
You can do it, have a go!
Contact: James Neale,
VANZ Conference 26th, 27th & 28th May 2015
Wairakei Resort Taupo New Zealand
New in 2015! One way or another everyone contributes to the lack of reliability of our assets and equipment,
therefore everyone should constantly strive to gain a greater understanding about reliability improvement
and condition monitoring techniques. Using a combination of informative “101” presentations and hands-on
sessions with industry experts, mechanical, electrical, apprentices, operators, supervisors and managers can
learn a great deal about the techniques that create a safer and more profitable workplace.
A Conference of Your Peers
Improving reliability and condition monitoring are vitally important to all
forms of industry, and the practicing engineers, analysts, and technicians are
a special breed of people. But where do you turn to for support? Where can
you meet like-minded people to share your frustrations and triumphs? The
VANZ annual conference, in its 26th year, is your conference.
It is not another talk-fest with the same presentations as the previous years;
VANZ has adapted to meet your needs to include round-table discussions,
hands-on learning sessions, mini-practitioner “war stories”, and social events
where you can have informal discussions with your peers. And yes, there will
be technical presentations from local and international speakers to provide
opportunities to increase your knowledge and reinforce what you have
previously been taught.
Call for Papers VANZ 2105
One of the unique features of VANZ is that the speakers are chosen on their
merits; not according to their sponsorship fees. But we need to hear from
you. Have you been involved in a process that had a positive outcome – a
diagnosis that lead to corrective action that solved a problem? Come along
and tell the story. Or what about a process that did not end well? Was there
an important lesson learned? Come along and tell your story! Remember,
presentations don’t have to be about the toughest diagnosis that stumped
the experts, or involve unique pieces of equipment; they need to be about
real-life challenges that others can learn from. And they don’t need to be 45
minute dissertations; just a 15 minute story is fine too. And don’t worry
about being heckled by the attendees; you are among friends. Please contact
James Neale to learn more [we have a team of people available to support
and encourage all presenters].
New Interactive Awareness Day Format! Get Hands On.
Exhibitors and Sponsors - Expressions of Interest Welcome - [email protected]
VANZconference2015
26th Annual Conference. May 26th, 27th and 28th.
Wairakei Resort, Taupo, New Zealand
www.vanz.org.nz
For further information or to secure your position please contact our conference team,
Leanne on +64 9 296 1333, Glen Pepper +64 21 897 547, or Cameron on +64 21 766 123
You can email us at [email protected] www.vanz.org.nzDesigned by www.flash-point.co.nz
GOLD EXHIBITORS SILVER EXHIBITORS BRONZE EXHIBITORS
www.vanz.org.nz - www.greatlaketaupo.com - www.wairakei.co.nz
Brevini New Zealand Ltd - 9 Bishop Croke Place East Tamaki - Web: www.brevini.co.nz - 09 250 0050
Together to make a difference
The VANZ Annual Conference and Awareness Day is the premier networking opportunity in both New Zealand and Australia to get your maintenance front line staff motivated and up to date with World Best Maintenance Practices and Reliability Engineering Solutions.
The initial VANZ workshop and conference was held in 1989 with around 80 delegates; since then VANZ conferences have consistently attracted many hundreds of delegates from all over New Zealand, Australia and the world.
VANZ conferences have been highly successful because of the basic agenda - a friendly open forum where front line staff are encouraged to share experiences, network with other industry colleagues and evaluate vendor technologies and practices.VANZ invites a world recognized authorities in reliability engineering and maintenance practices to present informative and motivating presentations at each conference.
The conference also features a wide range of innovative papers and case studies direct from a variety of New Zealand and Australasian industries. These include Pulp & Paper, Forestry, Dairy Industry, Petrochemical, Food and Beverage, Infrastructure and Power Generation companies.
We need your papers now.
You can do it, have a go!
Contact: James Neale,
VANZ Conference 26th, 27th & 28th May 2015
Wairakei Resort Taupo New Zealand
New in 2015! One way or another everyone contributes to the lack of reliability of our assets and equipment,
therefore everyone should constantly strive to gain a greater understanding about reliability improvement
and condition monitoring techniques. Using a combination of informative “101” presentations and hands-on
sessions with industry experts, mechanical, electrical, apprentices, operators, supervisors and managers can
learn a great deal about the techniques that create a safer and more profitable workplace.
A Conference of Your Peers
Improving reliability and condition monitoring are vitally important to all
forms of industry, and the practicing engineers, analysts, and technicians are
a special breed of people. But where do you turn to for support? Where can
you meet like-minded people to share your frustrations and triumphs? The
VANZ annual conference, in its 26th year, is your conference.
It is not another talk-fest with the same presentations as the previous years;
VANZ has adapted to meet your needs to include round-table discussions,
hands-on learning sessions, mini-practitioner “war stories”, and social events
where you can have informal discussions with your peers. And yes, there will
be technical presentations from local and international speakers to provide
opportunities to increase your knowledge and reinforce what you have
previously been taught.
Call for Papers VANZ 2105
One of the unique features of VANZ is that the speakers are chosen on their
merits; not according to their sponsorship fees. But we need to hear from
you. Have you been involved in a process that had a positive outcome – a
diagnosis that lead to corrective action that solved a problem? Come along
and tell the story. Or what about a process that did not end well? Was there
an important lesson learned? Come along and tell your story! Remember,
presentations don’t have to be about the toughest diagnosis that stumped
the experts, or involve unique pieces of equipment; they need to be about
real-life challenges that others can learn from. And they don’t need to be 45
minute dissertations; just a 15 minute story is fine too. And don’t worry
about being heckled by the attendees; you are among friends. Please contact
James Neale to learn more [we have a team of people available to support
and encourage all presenters].
New Interactive Awareness Day Format! Get Hands On.
Exhibitors and Sponsors - Expressions of Interest Welcome - [email protected]
VANZconference2015
26th Annual Conference. May 26th, 27th and 28th.
Wairakei Resort, Taupo, New Zealand
www.vanz.org.nz
For further information or to secure your position please contact our conference team,
Leanne on +64 9 296 1333, Glen Pepper +64 21 897 547, or Cameron on +64 21 766 123
You can email us at [email protected] www.vanz.org.nzDesigned by www.flash-point.co.nz
GOLD EXHIBITORS SILVER EXHIBITORS BRONZE EXHIBITORS
www.vanz.org.nz - www.greatlaketaupo.com - www.wairakei.co.nz
10_E
N_0
1111
4
Unit D/38 Highbrook Dr, East TamakiPh: (09) 2717 234
Specifications are subject to change without notification.
www.machineryhouse.co.nz
120 x 120mm notching capacity - mild steel 3mm thick mild steel capacity A transparent safety blade guard enables scribed lines to be quickly and accurately lined to cutting blade Roving foot pedal controls cutting action Includes adjustable pressure regulator and water filter trap Adjustable material stops and guides on both sides of the cutting blade
PN-130Pneumatic Sheet Metal Notcher
150mm x 150mm notching capacity - mild steel 1.6mm thick mild steel capacity Cuts to 150mm x 150mm at 90º Stroke on ram 20mm Bottom blades have 4 cutting edges Adjustable guides Cast base and body insures extreme rigidity and durability Weight 95kg
N-16S Sheet Metal Notcher Stand
N-16Manual Sheet Metal Notcher
200 x 200mm notching capacity - mild steel 4mm thick mild steel capacity A transparent safety blade guard enables scribed lines to be quickly and accurately lined to cutting blade Adjustable material stops and guides on both sides of the cutting blade Roving foot pedal controls cutting action that incorporates a pedestal emergency stop Heavy constructed cast iron working table Scrap material is ejected out from rear of machine 2.2kW / 3hp, 415V motor
HN-200 Hydraulic Sheet Metal Notcher
PO# 6235 | Sent 15/10/14
ENGINEERING NEWS | published 01-11-14
PN-130PNEUMATIC
HN-200HYDRAULIC
N-16MANUAL