Industry News

Enel X is the only contracted party to provide 95MW of Demand Response firming capacity in NSW, to help meet the energy security target. With increasingly challenging grid conditions due to weather conditions, low wind and hydro output, coal outages, and spiking electricity prices, flexible demand is an increasingly critical resource for firming the grid and putting downward pressure on electricity prices for all consumers. Businesses and organisations in the greater Sydney region can provide flexible demand—the inherent ability to adjust when grid power is used—as part of Enel X’s Virtual Power Plant (VPP) to help ‘firm’ the grid and keep the lights on. Firming capacity helps the grid integrate renewable energy assets safely. Participants are paid both for committing to be available and for reducing grid energy consumption for set periods, generally only a few times a year. “Western Murray Irrigation has supported the grid across multiple Demand Response programs with Enel X’s VPP since 2020,” said Judith Damiani, Chief Executive of Western Murray Irrigation. “Participation is straightforward and works well for us. An automated system…

Pick-and-place robots are increasingly important in automated processes, such as assembly lines. With its EXPT, the automation specialist Festo offers an exact and dynamic solution for this. Operating at up to 150 picks per minute, the robot works continuously. For this, safe and gentle feeding of the cables to the gripper had to be guaranteed. The unique feature—a rotating additional axis—led to increased wear of the cables. With a unique energy chain for tight installation spaces and dynamic applications, including a rotation module, the cables are now safely guided at high rotation angles Problem Festo SE & Co. KG is a leading provider of automation solutions for processes and entire production plants. The manufacturer also includes its universal parallel robot, "EXPT," in its extensive product portfolio. The tripod-based pick-and-place robot works with high performance and precision and manages up to 150 picks per minute. Its design and control system enable flexible and cross-application use, enabling convenient implementation in applications with several robots in the production line. An A5 axis was to be implemented at the lower end…

Servo systems are increasingly finding their way into applications used by industry; everything from simple vertical filling machines to high-speed printing presses are using servos to improve their output. Harry Mulder, Product Specialist for Motion Products at Beckhoff Automation, explains that while some believe all servos are the same, there are, in fact, some clear differentiators. “It’s these differences that yield big benefits.” What sets Beckhoff apart from the rest, according to Mulder, is its wide selection of motors and matching gearboxes. “Each motor offers a range of feedback options - everything from resolvers for harsh environments to 24-bit multi-turn absolute encoders with SIL 2-rated safety. Beckhoff also supports EnDat, SSI, BiSS and other protocols, as well as providing input for secondary feedback systems.” One feature that rates very highly among end users is a single connecting cable between the motor and the drive, commonly known as One Cable Technology or “OCT”. “Using just one cable to carry power, braking and encoder signals is more cost-effective and so much more convenient than running separate cables. In addition, not having a…

Aluminium remains a key structural material used in multiple industries worldwide, and Tiwai Point is New Zealand’s only smelter. A significant investment in new robot welding equipment shows that Rio Tinto is firmly committed to a future in the Deep South. According to long-serving staff member Paul Cavanagh, Rio Tinto’s Tiwai Point has always been about its people, and that’s the driving factor in a recent upgrade and doubling of its robotic welding equipment. "It’s about keeping people away from the load. People and safety first,” he said. Tiwai Point has used robotic welding since 1995, and this is the second upgrade since 2008 – but this time, the number of robots has doubled, along with the addition of an extra robot for loading heavy steel pins, a previously manual task. Cavanagh, the crew leader for the rodding process, says recent uncertainty was in the rear-view mirror, with the smelter securing a 20-year deal for electricity supply. For some time, it was clear that the old system used to weld anode rods in aluminium production—around 550 are…

Hydraulic tooling and bolt tensioning specialist, Technofast is adding a new pipe fitting technology to its range as the exclusive distributor for HAELOK® in Australia and New Zealand. Swiss-engineered HAELOK® pipe fittings can be swiftly installed in under a minute, providing a secure metal-to-metal gastight connection without sealing elements and welding, which add time and cost to the process. Proven in service for more than 20 years in major European markets, the durable and efficient HAELOK® fittings apply to a broad range of applications, including power stations, high-pressure hydraulic lines up to 1270 bar for smaller sizes (up to four-inches at 250 bar), oil, gas, and petrochemical refineries (including offshore), navy, marine, and defence, acidic environments, heavy mine sites, steam and biogas lines in sugar mills, and hydrogen piping. “The HAELOK® range is a natural extension of our Technofast range, which is already focused on saving downtime by efficient bolt tensioning technologies applicable to similar industries,” said Technofast Founder and CEO, John Bucknell. A better connection HAELOK® fittings function using an axial crimp. They have a tapered press…

In a move set to strengthen Australia's domestic manufacturing sector, Capral Aluminium has entered into a strategic supply partnership with Tindo Solar, Australia's only solar panel manufacturer. This collaboration will see Capral supply extruded aluminium for Tindo's locally produced solar panels, with the potential for further expansion to support Tindo's future Gigafactory. This partnership marks a significant step for both companies as Tindo scales its operations to meet increasing demand. The initial supply arrangement signals a shift by Tindo towards prioritising local suppliers in the renewable energy sector. Capral operates several aluminium extrusion plants across the country and is recognised within the Australian market as a leader in the supply of 'LocAL' lower carbon aluminium. This partnership aligns with Capral's commitment to sustainability and supporting Australian industries. "Capral's collaboration with Tindo is a testament to the strength of Australian manufacturing,” said Luke Hawkins, Capral's Divisional General Manager of Industrial and Supply Chain. “While our initial focus is on meeting Tindo's current production needs, we are particularly excited about supporting their future Gigafactory with locally extruded aluminium. This…

In recent years, Porsche Werkzeugbau GmbH in Schwarzenberg, Germany, has advanced its mechanical machining to the highest technical level. Two large Starrag HSC machining centres, Droop+Rein FOGS, play a major role in this. The machines finish press tools for moulding skin parts of vehicle bodies with the utmost precision and produce surfaces with grinding quality. A premium car manufacturer should have a premium engineering plant. To ensure that the Porsche Werkzeugbau GmbH Schwarzenberg plant fulfils all of the preconditions for this, €40million was invested over the last five years to develop the tool-engineering plant to the highest possible level following the transition from KUKA. Among other things, the Schwarzenberg-based company used this money to set up two new production halls, purchase a new 25,000kN servo press for production-related tool try-outs and invest in retrofitting and new machine tools – including two Starrag HSC centres of the Droop+Rein FOGS 35 68 N40C type. In addition to this, mechanical production was completely overhauled and the production processes were restructured. All of these measures were based on a solid foundation. Beforehand, the whole…

Hexagon’s Manufacturing Intelligence division has unveiled ProPlanAI, an automated computer-aided manufacturing (CAM) programming tool that cuts the time it takes to program factory machine tools by 75%. Powered by Microsoft Azure services built into Hexagon’s cloud-based Nexus connectivity and collaboration platform for discrete manufacturers, the new artificial intelligence technology is the next step in the evolution of CAM programming, enabling machine shops to achieve operational excellence at scale. ProPlanAI was unveiled at the Microsoft Ignite Conference in Chicago. Hexagon’s AI application uses Microsoft’s Azure OpenAI Service, Azure Cosmos DB, and Azure Databricks to help manufacturing businesses of any size apply their institutional knowledge more quickly, easily, and thoroughly. It uses artificial intelligence (AI) to automate time-consuming process planning. ProPlanAI, due to launch in Q1 2025, will ‘learn’ from the data created by a company’s CAM programmers. This will enable manufacturers to automatically explore existing programming information to predict ideal outcomes tailored to a company’s preferences, production capabilities, and needs. Available within Hexagon’s popular desktop CAM software and powered by Nexus, ProPlanAI will continuously learn and adapt, ensuring programs are…

Welding thick-section steel can be 40% faster and use 60% less energy when Dynamic Beam Lasers (DBL) from Civan are used instead of hybrid welding. These are just two of many remarkable results of a collaborative study by shipbuilder Fincantieri and welding systems firm Castellini, which shows that DBL technology is set to revolutionise shipbuilding and has the potential to transform thick-section welding for other manufacturing industries. Hybrid welding, which combines laser and Metal Inert Gas/Metal Active Gas MIG/MAG technologies, is the advanced approach for thick-section welding in shipyards. Improvements in welding are crucial because ships often require 300 to 600 kilometres of weld seams to ensure structural integrity. John Grace, physicist and Managing Director of Raymax Applications, which distributes Civan equipment in ANZ, believes the control and power now provided by DBLs not only weld thick sections faster but are also more economical and sustainable. “Unlike traditional lasers, which produce a fixed beam, Dynamic Beam Lasers can adjust the beam's shape, intensity, and size in real-time. This flexibility, increased precision, and control make them highly effective for…

Jaunt is an automotive workshop reinventing four-wheel drives and classic cars through electric conversion. Swapping engines from internal combustion to electric allows people to enjoy their vehicles while reducing their environmental impact. Despite the political word salad in 2019 Canberra about electric cars ‘ruining the weekend’, Australia has been converting cars to electric since the 1970s. In fact, the Australian Electric Vehicle Association (AEVA) is one of the oldest electric vehicle associations in the world. Dave Budge and his business partner Marteen Burger had “worked together with some great engineers and designers on making emerging tech beautiful and saleable,” explained Budge. “We both enjoyed camping and four-wheel-driving. I owned a Land Rover, but I wished it was electric, and there was no electric 4x4 on the market.” Budge had worked as a consultant with Holden and General Motors globally for a long time, which familiarised him with automotive sales stats. “Australia buys more four-wheel drives than anyone else, and the only electric cars were sedans…

Any company successfully operating for over 55 years has to recognise emerging market trends and adapt and evolve to meet those needs. Padstow-based D&D Smith Metal Pressers is one such company. The company was established by Dennis Smith and his business partner Bruce McEwan as McEwan & Smith. Their business began with just a couple of machines in Dennis’s father’s back shed, but after the first year of operation, they had grown enough to rent a property. Later that decade, they bought the premises, and Dennis built a new factory with his own hands on the site. The company took advantage of the boom in metal-stamping in Sydney during the 1980s and soon became an acknowledged expert and leader in the metal stamping industry. Dennis was passionate about improving quality and efficiency and, during this period, implemented a fully accredited quality system to ISO9002 standards. The current owner, Daniel Smith, son of Dennis, began working for the company in 1998 when he was 22, and the company was subsequently renamed D&D Smith Metal Pressers and Production Engineers P/L. In…

CSIRO, Australia’s national science agency, and Murdoch University have launched the Bioplastics Innovation Hub. This $8m collaboration will collaborate with industry partners to develop a new generation of 100% compostable plastic. The Bioplastics Innovation Hub aims to revolutionise plastic packaging by developing biologically derived plastic that can break down in compost, land, or water. Dr Andy Whiteley, director of the CSIRO Research Program, said the Hub aims to bring together experts in microbiology, molecular genetics, synthetic biology, biochemical engineering, advanced manufacturing, and the circular economy by translating advancements in bioplastics research into real-world applications. “Our primary focus is the development of 100% compostable, bio-derived packaging for use as sprays, films, bottles, caps and wrappers, which are engineered to break down in compost, land and aquatic environments fully,” said Dr. Whiteley. Global concerns over plastic pollution and fossil fuel depletion are driving increased demand for compostable bioplastics. The Hub will equip the plastics industry with the tools and expertise required to manufacture materials and continue to drive a green plastic waste economy. "It is critical to address the growing…

Many factors contribute to the successful manufacture of vacuum windows. Understanding and using cutting-edge technology, quality control via state-of-the-art metrology tools, and material properties are critical to their design and manufacture. Combined with a culture of innovation and in-depth and broad experience in precision optics manufacture, these technical capabilities can be honed to ensure optimal vacuum window manufacturing. What are vacuum windows? Vacuum windows are components designed to separate different environments while allowing light to pass through. They are commonly used in applications where a controlled atmosphere, such as a vacuum, must be maintained on one side of the window while allowing optical observation or the passage of laser beams. They are made from materials with high transparency to specific wavelengths of light and excellent mechanical strength. Common materials including fused silica (known for its low thermal expansion and high transparency in the ultraviolet to infrared range), sapphire (extremely hard and durable, suitable for harsh environments), borosilicate (excellent thermal resistance, low thermal expansion, and high chemical durability); and Zinc Sulfide (high transparency…