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SouthMach Manufacturing and Electronics Exhibition

24 - 25 May 2017

Wednesday 24th 9am-6pm
Thursday 25th 9am-4pm

Horncastle Arena Christchurch

Exhibitor Enquiry

Visitor

Information

Exhibiting

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Industry

Education

Warehouse stationary
Work Safe New Zealand
University of Canterbury
Ford
NZ Manufacturer
Maintenance Engineering Societ
NZMEA
IEDA
Engineering News
DEMM engineering & manufacturi
Warehouse stationary
Work Safe New Zealand
University of Canterbury
Ford
NZ Manufacturer
Maintenance Engineering Societ
NZMEA
IEDA
Engineering News
DEMM engineering & manufacturi

All-of-sector meeting tackles housing issues

New Zealand’s building and construction sector is facing the largest challenge of a generation.

New Zealand’s building and construction sector is facing the largest challenge of a generation.

New Zealand’s building and construction sector is facing the largest challenge of a generation. Auckland housing, the Canterbury rebuild, booming house prices, a lack of resource supply and the aftermath of the global financial crisis are just a few of the issues calling for an all-of-sector forum next month.

The Registered Master Builders Association (RMBA) is leading Constructive, a forum held in Christchurch from 21-23 September. Attendees will address New Zealand’s key issues with a view to improving outcomes and performance for all.

David Kelly, Chief Executive of RMBA says Constructive is a fantastic opportunity for the wider building and construction sector to engage with the issues as a whole. Those attending include economists, financiers, insurers, councils, regulators, engineers, builders, architects, quantity surveyors, planners and industry training organisations.

“Housing is New Zealand’s number one issue right now, the Government and the sector need to come together to tackle these challenges and discuss strategies to overcome them,” he says. “Constructive is the first time this broad group will come together. It will play a critical role in New Zealand’s development.”

Finance Minister and Deputy Prime Minister Bill English, along with Building and Housing Minister Nick Smith, intend to discuss the importance of the construction sector to New Zealand’s economy and the challenges that we face ahead.

A number of speakers from a range of disciplines in the building and construction sector will also share their views and participate in discussions to develop strategies for New Zealand’s future success. The speakers and facilitators include:

  • David Kelly, Chief Executive, Registered Master Builders Association
  • Connal Townsend, Chief Executive, Property Council New Zealand
  • Teena Hale Pennington, Chief Executive, New Zealand Institute of Architects
  • John Coop, Chairman and Regional Principal of Warren and Mahoney
  • Chris Parker, Chief Economist Auckland Council
  • Mark McGuiness, Managing Director, Willis Bond & Co
  • Gary Walker, Executive General Manager, Hawkins Construction
  • Craig Price, Director and South Island Regional Manager, Beca Ltd
  • Mike Greer, Managing Director, MHG NZ Ltd
  • John Bridgman, Industry Director, Civil Infrastructure, AECOM
  • Andrew McKenzie, General Manager Finance, The Fletcher Construction Company Ltd
  • Murray Sherwin, Chair, New Zealand Productivity Commission
  • Sir Maarten Wevers, Chair, EQC

David Kelly is pleased with the quality and breadth of speakers lined up for the forum.

“It’s fantastic that we have such a strong group of leaders who will be working with us to address the issues we’re facing. If we work together we can ensure our sector is strong, and moves in a positive direction,” he adds.

The speakers will discuss a broad range of topics including lessons to be learned from the challenges that arose from the Canterbury earthquakes, the impact of the global financial crisis, industry changes and emerging trends and issues.

Constructive will consist of informative and interactive panel discussions on topical issues within the industry, followed by a series of site visits/tours. Various industry leaders will be attending the forum which takes place on 21-23 September 2016.

The forum will be formally opened at a cocktail function on Wednesday 21 September.  The panel discussions will take place on Thursday 22 September with a gala dinner to follow and then the site visits/tours on Friday 23 September.

Registrations can be made via this link. For more information, visit www.constructive.org.nz.

To set up an interview with one of the speakers, or for further information please contact:

Frances Coles
Acumen Republic for Registered Master Builders Association
D: 04 494 5126
M: 022 071 9115
E: fcoles@acumenrepublic.com

The post All-of-sector meeting tackles housing issues appeared first on NZ Engineering News.

Food safety drives high performance plastics demand

Safeguarding safety and hygiene is a priority for the food, beverage and agribusiness industries

Safeguarding safety and hygiene is a priority for the food, beverage and agribusiness industries

Higher safety demands faced by food, beverage and agribusiness processors and packagers are driving demand for advanced engineering plastics to withstand the demands of the latest cleaning and hygiene systems.

Clean in Place (CIP) systems, enzyme systems and aseptic packaging are important areas where such plastics can offer high performance in terms of resistance to temperatures, radiation, chemicals and water.

Efficient food packaging equipment no longer has to be disassembled for cleaning, being fitted instead with a built-in “flush” (or CIP Clean in Place) system, says Pat Flood, NSW manager of the national and international engineered plastics specialist Cut To Size Plastics.

Acid-based cleaning solutions are automatically routed through CIP machines’ plumbing so the tear-down and set-up cycles that previously took many hours can be reduced to a matter of minutes.

Better hygiene and equipment utilisation outcomes are also produced by advanced agribusiness systems where enzymes are used for cleaning tanks and equipment such as ultrafiltration membranes or heat exchangers in the dairy industry.

Both CIP and enzyme systems make demands on the materials with which they come in contact. CIP systems are generally acid-based or, more commonly, chlorine-based. Depending upon the concentration, these cleaners can be moderately to extremely caustic. Plastics such as our Wearlyte PET (polyethylene terephthalate) are highly resistant to acid and chlorine. At the same time, its non-porous surface resists staining, clearly outperforming widely used alternatives,” says Mr Flood.

Wearlyte PET’s dimensional stability, excellent wear resistance, high strength and its ability to be used continuously at higher temperatures also make it an ideal candidate for replacing stainless steel components. For example, coupled with its stiffness and ease of fabrication, Wearlyte is commonly used in food presses. Here too, the material resists the highly-chlorinated sanitising solutions.

For packaging food in plastic containers under sterile, or aseptic, conditions, a variety of engineering plastics can be selected to operate in the higher operating temperatures required to kill bacteria. Under these conditions, traditional materials like polyethylene may not provide adequate physical strength, says Mr Flood. Cut to Size products such as Peek (Polyether ether ketone) High Temperature, on the other hand, retains its high mechanical and impact strength, stiffness and dimensional stability at elevated temperatures. It is one of the few plastics compatible with ultra-high vacuum applications.

In addition, Peek thermoplastics offer an excellent wear resistance over a wide range of working conditions. As a result, for example, distribution valves made of such materials are increasingly replacing stainless steel parts, which cause valve housings to wear easily and result in high maintenance costs.

Materials such as Wearlyte PET are also preferred over stainless steel in order to minimise wear of the expensive mating part in vacuum shoes on high-speed, high-volume food packaging lines.

Cut to Size’s general-purpose Wearace grade, meanwhile, is especially suited to create durable wear components because of its excellent versatility, dimensional stability and good wear properties. Easier to machine than stainless steel, Wearace is a superior material because of its limited expansion and low moisture absorption during process and cleaning applications.

Cut To Size Plastics manufactures components for applications across Australasia and the Asia-Pacific from its Head Office in Sydney, where facilities include CNC machining facilities coupled with GibbsCAM and Solid Works software.

The post Food safety drives high performance plastics demand appeared first on NZ Engineering News.

Sewage treatment upgrade withstands nature’s fury

 

An upgrade of a council sewage treatment plant in Australia certainly proved timely for the local body.

An upgrade of a council sewage treatment plant in Australia certainly proved timely for the local body.

An upgrade of a council sewage treatment plant in Australia certainly proved timely for the local body.

The Richmond Valley Council upgrade of its Casino Sewage Treatment plant has paid immediate dividends by withstanding the fury of June’s storms and flooding without suffering any polluting spills or odours.

The turnkey upgrade – which included retrofitting of fine screening technology by CST Wastewater solutions – was completed just days before the bad weather along Australia’s East Coast dumped more than 160mm of water on the council region within 48 hours.

The Council couldn’t have timed the upgrade any better. Their foresight and technology upgrade was perfect,” says CST Wastewater Solutions managing director Michael Bambridge. “The Northern Rivers District of NSW is one of the most flood-prone areas outside of the tropics, where events like this are likely to occur and reoccur, so the investment in new technologies has already paid off.”

The retrofit project – of a type that is applicable to councils and industrial uses throughout Australia and New Zealand – replaces the previous coarse raked screen design with current fine screening technology. This captures more solids to reduce potential blockages in tanks and downstream equipment, while reducing odours by sealing the inlet works and by the installation of new odour control units.

The project’s high-efficiency fine screening SFC technology (screen press for channel installation) is engineered to deliver low-maintenance performance with reduced WHS hazards for municipal and industrial waste water operators.

The SFC allows for a much finer level of screening – 5mm compared with typical old systems at 60mm or more – which has led to a significant reduction in solids in the tanks, while producing more efficient treatment with less maintenance

The retrofit also involved the installation of an SDS 20 compactor with two inlets – one for each screen – to dewater screenings to 25-30% dry solids. Each screen has an enhanced design capacity of 250L/s flow, providing a total capacity of 500L/s.

Technology transplant

The original inlet works at Casino STP were designed with a coarse manual raked bar screen system. The functional components of the treatment process downstream of the bar screen receive a high amount of debris, which formerly impacted the efficiency of the treatment process. The original inlet area also received a high amount of odorous gases, which previously contributed significantly to odours emanating from the treatment plant.

In addition to minimising these issues, the upgrade project involved fitting new technology into an existing layout, including tailoring the screens to fit into the existing formed channel.

The SFC technology involved in the retrofit – designed to lower investment, operational and maintenance costs in screening of municipal and industrial waste water with compacting of extracted solids – has also cut the amount of maintenance and waste that has to be handled by plant operators, reducing operational health hazards and improving OHS performance.

The same benefits are widely applicable to other industry and municipal applications, says Mr Bambridge.

The technology is also suitable for applications such as food and beverage, manufacturing and processing, mining, energy and resources camps where its low maintenance/high hygiene qualities are appreciated, agribusiness, and remote installations where low maintenance and high efficiency is a priority for users who don’t need to have specialist staff constantly available.

Not only are the tanks clearer and more efficient now, but the screen extractor also operates on level control and is fully automated, eliminating the previous labour-intensive operator handling of screenings,” he says.

The robust and proven extractor is constructed from AISI 304 or 316 stainless steel without the need for hanger, intermediate or bottom bearings. Featuring a space-efficient design suited to small sewage plants, the standard unit can handle up to 1000m3 an hour with custom engineering also available for particular installations. A vertical version is also available to easily retrofit into existing pump stations with depths up to eight metres, the screen allows removal of material before pumping, says Mr Bambridge.

The versatile SFC screen extractor can be installed in a channel or supplied with self-supporting tank, complete with inlet and outlet flange and optional bypass screen.

CST Wastewater Technology packages

New engineer-and-build water and waste water treatment and recycling packages from CST Wastewater Solutions are aimed at industries and municipalities that want to lower the cost and complexity of such projects.

The design, supply and install packages – incorporating global and locally manufactured technologies proven in use by some of Australia and New Zealand’s leading companies and councils – are aimed particularly at:

Councils seeking engineering assistance to develop clear choices and optimum solutions incorporating advanced low-maintenance technologies providing high levels of water purity while reducing maintenance, waste handling and OH&S issues associated with running them.

Industries seeking readily constructed or portable, low maintenance solutions for operations particularly in remote, ecologically or environmentally sensitive areas – ranging from resources or agribusiness developments in the country or outback, through to food, beverage, manufacturing and processing plants sharing precious water resources with urban areas.

Rather than presenting such organisations with a jigsaw of disparate collections of technologies and engineering services options for them to piece together, the packaged solutions focus on clear, properly engineered solutions that deliver what they promise. CST offers turnkey solutions based on a known raw water quality and guaranteeing water quality outcomes thus giving user engineers significant confidence in the outcomes and limiting their exposure and potential concerns, says Michael Bambridge.

CST Wastewater Solutions has been involved in projects, technologies and services that increase environmental sustainability since its inception over 25 years ago. CST represents Global Water Engineering (GWE) technologies in Australia that are at the forefront of waste-to-energy initiatives, cleverly turning a problem, wastewater, into a profit, biogas, which can be used to power boilers, reduce fossil fuel use and converted to electricity.

The post Sewage treatment upgrade withstands nature’s fury appeared first on NZ Engineering News.

Purchase of an ‘Englishman’ increases productivity 30 percent

A press brake, guillotine and other engineering machinery complement the new Swift-Cut plasma cutting table

A press brake, guillotine and other engineering machinery complement the new Swift-Cut plasma cutting table

Gary Wight of Auckland Sheet Metals makes no bones about it; the purchase of a new Swift-Cut plasma cutting table from Machinery House – the ‘Englishman’ as it’s affectionately known in the workshop – has increased business efficiencies by 30 percent.

Mr Wight wonders what they ever did without the machine: “It doesn’t get sick, never stops working and every cut is a classy finish,” he tells Engineering News.

He says the company has been at its current premises for close to 10 years, with most of that in partnership, but the real business evolution has occurred in the past two years when he “went it alone”.

It meant I could invest in machinery,” he says, talking about the dissolving of a partnership that had two owners wanting to pull the business in different directions. “The last two years we’ve been Auckland Sheet Metals – in sole charge – and I’ve bought new presses, welders, the plasma, vehicles that have made life easier and the result has been more progress in the last little bit than the whole time of being in business prior to that.”

And since the change they’ve “been struggling to keep up. I’ve made it a focus to buy machinery that keeps the work going while we aren’t”. The ‘Englishman’ (a derivative from its country of origin) does exactly that.

He says the plasma machine can be cutting and making parts while his workshop engineers crack on with the welding. “It’s actually given us more man power. To make those parts the old fashioned way, with less accuracy, would take hours longer and this machine never stops.”

Mr Wight adds that the machine was only just installed before EMEX 2016, but despite it being early days he estimates that the Swift-Cut improves the jobs they are using it for by as much as 30%.

I wouldn’t be without it now,” he says, explaining that before to the installation they would have to outsource work, and also rely on other businesses being efficient and delivering to timeframes.

We can continually change things, tweak things, make things better, and if there are ever any problems we just pick up the phone to Machinery House. It’s allowed us in great part to control our own destiny.

We actually end up making a little bit more money on the side because you become almost a merchant of materials, putting mark up on the material we are buying in as well as making money on cutting the product. The local businesses that use our services have responded so well… the new plasma has such a clean finish, we’ve got people asking us for more laser cut plates, thinking we are laser cutting it.”

Business has grown through word of mouth and the quality of the jobs they do has meant Auckland Sheet Metals don’t even need a website as they have enough on their plate.

Ten staff do a large range of work; stainless steel to structural steel at former All Black John Kirwan’s house. Structural steel is a growth area for the business, thanks to legislation with regard to steel in housing and earthquake regulations.

The premises houses a 4m guillotine (up to 8mm thick), 4m press brake (135 tonnes also purchased from Machinery House), band saws Mig and Tig welders, rollers and all the general equipment you’d expect of a good engineering workshop, but the plasma has quickly taken pride of place.

For our size business it’s a perfect fit. It’s not top of the market in terms of price and/or function, but it’s pretty bloody good and also easy for the staff to handle.”

Another staff member is kept busy fulltime draughting and quoting jobs so “we have a bit of a one-stop shop when it comes to that and our customers are dealing with one person through the process.

Most of the guys are trained and qualified sheet metal workers, which is pretty hard to say nowadays and that’s a feather in our cap,” says Mr Wight.

Mr Wight loves the engineering industry, having started work with Morris Sheet Metals in Onehunga as a 15-year-old sweeping the floor.

Today, armed with the Englishman and a highly efficient staff and workshop, Auckland’s houses crisis will do nothing but add to an increasing workload that already has him eyeing larger premises.

Whether it be residential, commercial, maintenance, structural or repairs, with Auckland Sheet Metals Mr Wight, his team and the Englishman are a cut above the rest.

The post Purchase of an ‘Englishman’ increases productivity 30 percent appeared first on NZ Engineering News.

Toshiba motors and drives to thrive as standards rise

Gustav Eiselen gets a first hand look at motor efficiency testing at Toshiba's test facility in Sydney, Australia.

Gustav Eiselen gets a first hand look at motor efficiency testing at Toshiba’s test facility in Sydney, Australia.

Worldwide efficiency standards dictate that New Zealand and Australia will, in the near future, need to adopt the much higher IE3 MEPS-3 Standard for premium efficiency motors.

Gustav Eiselen minces no words, there’s winds of change about to set upon the local industrial motors and drives scene as Europe battles to meet new eco design regulations. Europe’s electric motor efficiency regulations that came into force at the start of 2015 have not resulted in the expected boost to sales of high-efficiency IE3 motors. Under the Ecodesign regulations, common types of motor with ratings up to 375kW placed on the market since January 2015 must either meet the IE3 efficiency level, or meet the lower IE2 level and be fitted with a VSD (variable-speed drive).

In the next phase of the Ecodesign regulations, which comes into force at the start of 2017, the ratings of motors covered will be extended down to 750W. The option of either buying an IE3 motor or using an IE2 machine with a VSD will remain but, from 2018, the European Commission will eliminate the IE2+VSD option.

Mr Eiselen says that the new standards provide a perfect time for New Zealand Industrial Electric Co (NZIND) to shine under its appointment as the master distribution agent for Toshiba in New Zealand and the Pacific Islands.

All motors sold in Europe from January 2015 have to meet the stringent IE3 standards up to and inclusive of 375kW and these new standards will result in New Zealand and Australia being forced to tow the line in the near future, and adopt the much higher IE3 MEPS-3 Standard for premium efficiency motors.

This represents a major shift in the market and will present a challenge to all motor suppliers in New Zealand and Australia. The new standard no longer allows ‘Test Method B’, which allowed suppliers to use assumed figures for their testing calculations,” says Mr Eiselen.

In his role as sales and marketing manager with the 100% New Zealand owned and operated NZIND, Mr Eiselen explains that for Toshiba to partner with the Kiwi company it meant a new design of a number of its motors to ensure “we not only met, but exceeded the requirements of the higher MEPS-3 standard”.

According to Mr Eiselen, the decision to represent Toshiba products, especially the motor division, was not taken lightly.

We have a very mature market in New Zealand with a number of established brands. The differentiator for us will be the fact that Toshiba offers a genuine world leading alternative to current brands and those on offer in New Zealand.”

He says that Toshiba has long been regarded as one of the premium brands in motors and drive technology worldwide and is not a new brand in New Zealand, by any stretch. Some of the largest industrial installations in the pulp and paper industry, power generation steel manufacturing, oil and gas have Toshiba motors as part of their primary plant.

NZIND represents the industrial range of Toshiba products, with “our main focus on electric motors and drives. Our offering also includes a range of instrumentation and award winning LED industrial lighting products”.

Mr Eiselen says that local industry in New Zealand, such as those involved in electrical engineering, are continually looking to future proof plant and control equipment. With new standards on the horizon, today when buying a new motor there is a need to satisfy yourself that you are buying a product that will meet future efficiency standards.

Motors supplied in New Zealand are dynamically balanced to ISO 1940 G2.5. All Toshiba motors are dynamically balanced in the factory to ISO 1940 G1.0. A higher balance grade is a huge benefit to clients – reducing vibration and extending the life of the motor bearings. This is a very significant differentiator for Toshiba.”

Mr Eiselen explains that NZIND stocks over 1000 motors in its central North Island warehouse and services the South Island, lower North Island and central North Island. NZIND has appointed a reseller – Rotech Pacific, who stock motors for NZIND’s Auckland and Northland customers. Rotech Pacific provides motor sales service and maintenance, in-house or on-site.

NZIND offers customers an end-to-end sales and service experience. We sell, service and support our products nationwide. We can assist our customers with detailed design support, specification on product and full commissioning of products sold.”

NZIND also offers a full maintenance, on-site inspection, installation and a complete motor service package to all existing and new customers from its facility in Kawerau, Bay of Plenty. “We are genuinely a one-stop-shop when it comes to motor sales and support” and the Toshiba agency adds to its weight.

The buck doesn’t stop there with NZIND. “We are one of the leading industrial LED suppliers in New Zealand, Mr Eiselen says, adding that the LED product was introduced to provide a balanced offering to its industrial clients.

Lighting is such a big issue on sites. Most site maintenance staff are bombarded with suppliers all offering LED lighting. Without in-depth experience in LED lighting technology, it is very difficult for them to make an informed decision about which product to buy.

What people do not realise is how important it is to have a good design philosophy when you are looking at LED lighting. A good LED design is based on various electrical/electronic and mechanical design principles. NZIND offers customers a full turnkey service starting at understanding the application, providing a detailed LED lighting model and the selection of a suitable product that will exceed the requirements based on solid industrial engineering principles.”

No matter the size of the project, NZIND’s focus is to build long-term relationships based on trust, support, service and sound engineering advice. Consider NZIND the first stop when buying a new motor, drive, LED Lighting or instrumentation for your next maintenance or plant project.

The post Toshiba motors and drives to thrive as standards rise appeared first on NZ Engineering News.

Customisation: key component in NDA crane installation

Hamilton-based NDA Group went in search of a crane that could tackle a specific job; it needed a crane that would not only lift, but turn.

Hamilton-based NDA Group went in search of a crane that could tackle a specific job; it needed a crane that would not only lift, but turn.

Hamilton-based NDA Group went in search of a crane that could tackle a specific job; it needed a crane that would not only lift, but turn.

NDA’s core area of business is fabricating with specialty alloys and stainless steel for use in industry and when it came to construction of its stainless steel vessels the company needed not only a two hook system to lift then rotate the vessels, but also the added versatility of as much hook height as possible.

Enter Crane Hoist Lifting.

“We needed the right system that suited us and that meant that customisation was absolutely vital to suit our specific needs and facilities,” says John Smulders of NDA.

Crane Hoist Lifting installed two cranes with a capacity of six tonnes (two three-tonne hoists on each crane beam) and from that moment the focus was on the needs of the customer.

“Taking advice from Crane Hoist, we needed a twin hook system,” explains Mr Smulders,” but in the process of turning it means that the hook would not be above the lift point.”

NDA chose Street LX chain hoists instead of wire rope hoists as with a single girder crane they are more robust for rotating stainless steel vessels when compared to wire rope hoists that are susceptible to damage when the loads are not vertical.

The Street LX chain hoists have the added advantage of higher duty and good hoisting speeds when compared to standard chain hoists.

With the need also for as much hook height as possible, Mr Smulders says that Crane Hoist Lifting came to the party in terms of NDA’s specific needs.

“There was very limited headroom so it wasn’t fitted it with standard chain hoist but with a low headroom chain hoist.”

This meant that the hook could come a lot closer to the underside of the crane beam and added an additional 350mm hook height as opposed to a traditional three-tonne chain hoist.

“To add even more hook height, we then pedestaled the crane hook well above the end carriages and tapered the top of the beam to push it up even further,” explains Ian Young of Crane Hoist Lifting. “It was also necessary to fit longer end carriages to provide greater stability because of the high pedestal.

“The installation is the very latest in state of the art technology, twin hoist, rotating and lifting tanks, fully radio controlled with new generation low head room chain hoists. It’s exactly what NDA needed for the jobs they are undertaking.”

The operator can stand at the optimum position to make the lift thanks to the rubber-covered, shock-resistant SAGA-K2 industrial remote control, meaning they can position themselves safely away from the load and with optimum visibility.

The two hoists can “talk to each other” and operate in tandem or as a single hoist. Electrical limits ensure no overloading or accidental collisions (anti-collision and anti-approach technology) which meant that NDA could have two larger cranes installed than what would usually be suitable.

“Crane Hoist Lifting services both the crane and the controller and that gave us added peace of mind,” says Mr Smulders. “They met and exceeded our expectations and requirements.”

The post Customisation: key component in NDA crane installation appeared first on NZ Engineering News.

Mixing it Bonfig style

Advanced technology heavy drives are being custom-engineered by Bonfiglioli in Australasia to achieve optimum cost-efficiency and reliability with clean and robust service to aerate or mix liquids.

Advanced technology heavy drives are being custom-engineered by Bonfiglioli in Australasia to achieve optimum cost-efficiency and reliability with clean and robust service to aerate or mix liquids.

Advanced technology heavy drives are being custom-engineered by Bonfiglioli in Australasia to achieve optimum cost-efficiency and reliability with clean and robust service to aerate or mix liquids.

Bonfiglioli’s HDP parallel shaft helical gear drives are an outstanding new generation of large industrial gearbox assembled in Australasia to produce exceptional reliability and torque densities to record values, says the managing director, Bonfiglioli Transmission (Australia) Pty Ltd, Malcolm Lewis.

The drives feature excellent torque distribution across their entire ratio range, with gear ratios laid out in close progression and the drives having a rugged capacity to cope with the shock and impact of intermittent loads.

The full range of Bonfiglioli large parallel shaft gearboxes has been extended for the Australian marketplace, with output torque ranging from 4720Nm to 215480Nm. Bonfiglioli’s HDP range features a housing made from spheroidal cast iron; monobloc from HDP60 to HDP120 and horizontally split HDP130 to HDP160.

Bonfiglioli’s Drives Service Centre (DSC) enables Bonfiglioli to respond rapidly to local industry’s needs for drives required for prompt delivery to avoid costly delay or downtime.

Reliability in service is enhanced by the HDP drives’ finite element analysis and multi body simulations conducted extensively to identify the stress pattern on each of the main components and to optimize the design for:

• System structural stiffness

• Gear geometry

• Shaft deflection

• Extended gear and bearing lifetime

An Australasian example of the drives locally engineered for a waste water application cost-effectively integrated 55kW six-pole motors with HDP helical parallel series drive featuring output shaft dry well and a mechanically driven OP2 lubrication pump.

The drives – specified for 55kW power and 10 kNm output torque – incorporated an integral mechanically driven OP2 lubrication pump to ensure optimum bearing performance in vertical motor mounting arrangements.

They were also epoxy coated for optimum corrosion protection, cleanliness and durability. The drives incorporated an output shaft dry well feature to safeguard against oil leaks into process liquids as seals age and wear.

“While these particular drives were for aerators at a wastewater treatment plant, many of the features apply equally well to similarly robust process applications involving other infrastructure applications as well as challenging applications in food and beverage manufacturing and minerals processing liquids,” says Mr Lewis.

One of the outstanding flexibility features of Bonfiglioli’s new Australasian production and testing line for HD drives is that the company can readily adapt specific drives to particular applications.

“For example, drive bearings were engineered to accept greater loads generated by the long shafts found in aerator applications. The drives are also specifically configured for applications where they are mounted vertically,” he says.

Bonfiglioli’s HD series drives are also being incorporated into Bonfiglioli’s unique locally engineered drives including hi torque, alignment-free and power pack innovations.

Bonfiglioli has invested extensively in state-of-the-art production technology, backed by in-house technical expertise with major investments in stocking and service.

The post Mixing it Bonfig style appeared first on NZ Engineering News.

Bird’s Life in Brazil – Prosthetic Titanium 3D Printed Metal Beak

 

A beak for Gigi the macaw has been created with an Mlab cusing R from Concept Laser as 3D printing merges with veterinarian science

A beak for Gigi the macaw has been created with an Mlab cusing R from Concept Laser as 3D printing merges with veterinarian science

Sometimes a story from the world of 3D printing sounds so incredible you just don’t believe your ears. For the first time a prosthetic titanium beak has been manufactured using 3D metal printing and implanted on Gigi, a blue macaw (a genus of the parrot family), in Brazil. This unusual prosthetic saved Gigi’s life, as macaws are unable to eat solid foods without a beak.

The illegal trade of wild birds is a sad story of greed, and it doesn’t just happen in Brazil. The victims are magnificent creatures whose very beauty can end up being their downfall. During Gigi’s captivity at the hands of illegal bird traders, poor housing conditions caused severe malformation of the bird’s beak. Ultimately, Gigi was freed by the Brazilian police, but the magnificent bright blue and yellow feathered macaw could no longer be fed without a beak. A team of veterinarians, together with 3D printing experts from the Renato Archer Technology and Information Center (CTI) in Campinas, Brazil, developed an implant solution for the bird. The successful operation took place at the Animal Care Center in Ipiranga near Sao Paulo.

An interdisciplinary team effort

The artificial beak was created thanks to the cooperation of three specialists. The team, dubbed the ‘Avengers’, comprised veterinarian Roberto Fecchio, 3D designer and facial-reconstruction specialist Cicero Moraes and veterinary dentist Paul Miamoto.

The Avengers are pioneers in the use of 3D printing technology for saving the life of wild animals, having previously made a new shell for Freddy the turtle and a beak for an injured toucan. These prosthetics were made of plastic. In the case of Gigi, plastic was not suitable. Macaws use their beaks to open seeds and break other hard shells, meaning that their beaks need to be extremely long-lasting and strong. This being the case, the team decided on the extremely hard material titanium. Titanium presented itself as the perfect solution, as it is biocompatible, lightweight and corrosion-resistant. Many prosthetics for people are produced using titanium today, so why not try using the material to help a wild bird?

First LaserCusing, then a successful operation

Mr Miamo to began by taking a series of photographs of the malformed beak. From these, Mr Moraes created a digital 3D model for the perfectly fitting prosthetic. The beak was then laser melted at the Renato Archer Technology and Information Center (CTI).

Gigi’s artificial beak was created using a Mlab cusing R from Concept Laser, with which especially delicate parts with high surface quality can be manufactured. The smallest system model from Lichtenfels proved to be the right choice for saving Gigi’s life. The operation then took place at the Animal Care Center in Sao Paulo. Veterinarians Roberto Fecchio, Sergio Camargo, Rodrigo Rabello and Methus Rabello participated. The 3D-printed prosthetic was secured in place with bone cement and orthopedic screws. Just 48 hours after the operation, Gigi was able to try out the beak. She made a fantastic recovery at the Center for Research and Screening of Wild Animals (CEPTAS) at Unimonte University. Gigi is currently awaiting placement at a zoo, where visitors can marvel at the bird’s one-of-a-kind beak secured in place with colorful rhinestone-styled screws. The other birds are going to be seriously jealous.

Bottom line

All’s well that ends well. Examples like Gigi show that 3D-printed medical technology isn’t just capable of providing greater quality of life to people. The unlimited geometric freedom of the process enables the manufacture of perfectly fitting implants ideally suitable for each respective application. Ultimately, it was able to help a magnificent wild bird overcome injuries and deformities, so there is good news in our often uncertain and sometimes unsettling world.

The post Bird’s Life in Brazil – Prosthetic Titanium 3D Printed Metal Beak appeared first on NZ Engineering News.

Composite stainless/galvanised steel stirs up big interest

Imagine a stainless steel finish on one side and galvanised on the flip-side of a composite clad panel.

Imagine a stainless steel finish on one side and galvanised on the flip-side of a composite clad panel.

Imagine a stainless steel finish on one side and galvanised on the flip-side of a composite clad panel. A strong stainless steel finish out in front, and galvanised protection to boot in behind… but now imagine one third cheaper than the price of regular stainless steel.

Fresh to New Zealand comes a product that is causing a stir down in the deep south according to Gary Fahey, managing director of Composite Solutions, a subsidiary of Dan Cosgrove 2014 Ltd of Timaru.

“When I saw it I just had to go and see it for myself,” says Mr Fahey of the evolution from on-screen to an in-factory visit to supplier Changsong Group/ Simpson steel in ChangZhou, China.

Now, he has the sole distribution rights to Australia and New Zealand for the clad plate.

“We have the local council interested… imagine it in water, waste water and effluent tanks too, there’s a host of applications where people want the finish of stainless steel and its superior corrosion properties just on one side but also the protection of galvanised steel, which is well accepted on the outside in the atmosphere. This does both, but with a major cost advantage over normal stainless steel. Everyone I show this to experiences that ‘lightbulb moment’ where it clicks and the most common statement is, ‘It just makes sense’, explains Mr Fahey.

The stainless steel clad panel is manufactured from two components: top faceplate (stainless steel), bottom (galvanised steel) with a macromolecular polymer resin adhesive in between.

The macromolecular polymer resin forms an insulating barrier by total separation between the two dissimilar metals stopping electrolysis.

“It can be machined, laser cut, bent, punched,” says Mr Fahey, “it’s so very versatile while also highly aesthetic with that added peace-of-mind of galvanised insulation to protect it from environmental conditions and provide high corrosion resistance.”

The product is central to Changsong’s ‘green technology’ stable of products. 

He says there are limits to its use but within its parameters, Mr Fahey is adamant there is a strong market for what is a quality composite metal.

It has high elongation and can be easily processed and shaped, but there are added benefits as well with reduced vibration due to the polymer membrane (far greater than ordinary stainless steel), and sound insulation is also higher thanks to the interlayer’s viscous properties and a low through current means even greater electrical resistance. Yes, you read correctly, electrical resistance in a stainless steel.

Currently the product is in use in tank construction, irrigation pipes, elevators, escalators, industries requiring high food grade protocols and extensively used in the manufacture of whiteware.

Mr Fahey says his trip to China was an eye opener, with the manufacturing facilities simply “blowing him away”.

“I’ve never seen anything like it. It’s no wonder this composite material is making a stake for an international marketshare as it’s been put through all the testing cycles and has come out on top.”

The composite material is available with 304 and 316 grades of stainless steel and using the same process can have either copper or aluminium bonded to the galvanised steel as well.

P: + 64 3 687 9440 E: compositesolutionsltd@gmail.com

PO Box 974, Timaru. 31 Leckie St, Timaru 7910, New Zealand

The post Composite stainless/galvanised steel stirs up big interest appeared first on NZ Engineering News.

South Fence Machinery: Wired for Success

Christchurch-based South Fence Machinery knows the lay of the engineering land well, and it was ‘real estate’ and the need to maximise it that ultimately saw the investment in a brand new Okuma MU6300V-L 5-axis vertical machining centre - it’s done more than fill the gap.

Christchurch-based South Fence Machinery knows the lay of the engineering land well, and it was ‘real estate’ and the need to maximise it that ultimately saw the investment in a brand new Okuma MU6300V-L 5-axis vertical machining centre – it’s done more than fill the gap.

Christchurch-based South Fence Machinery knows the lay of the engineering land well, and it was ‘real estate’ and the need to maximise it that ultimately saw the investment in a brand new Okuma MU6300V-L 5-axis vertical machining centre – it’s done more than fill the gap.

Walking through the massive 52,000 square foot Sockburn workshop and you sense the Kiwi engineering No. 8 wire that has come before. Like tracking the growth of a child’s height with lines on a door frame, South Fence’s rich Kiwi engineering heritage is shown through a wide assortment of variously aged machines: mostly Okuma. It’s not a graveyard though, more of a fully-functional machining Mecca. All the machines are still in use, and get put to good use.

“It’s fair to say South Fence has had a long relationship with the Okuma brand,” co-director Martin Neill tells Engineering News with a welcoming southern smile. And he’s quick to point out, “our growth has come with a need for new machines and when it comes to that, and in today’s engineering environment, it’s what comes after the purchase that really counts today.”

The company has invested heavily as international demand has grown for its quality Kiwi-made wire fence machinery and associated equipment. Saying that South Fence is churning out machinery would not do credit to the quality, but with at least three machines a year on the books and high demand from overseas sources, Mr Neill knows that schedule is everything and down time is not an option.

“We have to know that if anything goes wrong there are places, people and parts to turn to. We get that from Okuma. Sure, the new machines we now have on site are faster, more functional and outperform previous models, however machine performance is only a small part of what our business needs from such heavy investment. Back up service and support is critical after the initial investment has been made,” says Mr Neill.

South Fence is the only New Zealand Company to manufacture a complete suite of wire fence machines – fixed knot, hinge joint and stiff stay, covering almost every fencing need from camels in desert sands to cows in gentle pastures; from deer in alpine meadows to security alongside motorways, rail tracks or surrounding buildings.

Co-director Ben Byers is in total agreement, explaining that for them it’s about getting as much as they can from what they have got through maximising efficiencies.

“All of these machines are basically real estate,” he explains, gesturing at the pure physical sizes of two older Okuma machines on site: MCV-A and MCR-A double column machining centres, both still playing a major part in the manufacture of necessary components for their wire machines. But Mr Byers isn’t talking purely of the machine taking up floor space, instead explaining that every machine has to produce parts that are a match for the machining capability available, allowing more efficient production of parts at the limits of the machines machining envelope.

“We have to find the most efficient and cost-effective ways to produce our machines to meet our current market and production demands. With the new Okuma [MU6300V-L] we’ve removed the small – medium sized parts from our larger machines and some of the more complex parts from our machining centres, streamlining the production process. We now have all bases covered and have the right machine for the job, big or small.”

Having a wide range of machining options also means the company can tailor each machine’s specifications to suit customer requirements, while also being able to offer a wider range of general engineering services to the wider Canterbury region.

“Every year we are expected to design and manufacture increasingly complex production machine solutions. To ensure we can use the current CAD/CAM packages efficiently and to continue producing the complex parts required to achieve this, our machine technology and machining techniques must be at the multi-axis/multi-tasking machine level,” explains Mr Byers, also highlighting the ability of multi axis machines reducing multiple machining operations.

With the right machines for the job, South Fence’s 25 staff design and build its wire fence machines for A to Z, using in-house technology and the latest manufacturing techniques to meet its own high quality standards.

The MU6300V-L is an impressive unit with both co-directors singing the praises of a machine that also “sings” sweetly as it works.

“Accuracy, capacity, versatility…. there’s not really much more you could ask for in a 5-axis machine,” says Mr Neill.

The MU6300V-L’s highly rigid trunnion table supports high accuracy 5-axis machining, while the machine’s efficiency and capacity is driven through intelligent technologies that allow excellent 3-axis machining and 5-axis machining with the additional ability of face, end and intricate CNC turning capabilities.

Operator access and visibility has been paramount in design and with a large machining range, tools can be changed with the trunnion still in swing position.

It’s these types of features that attracted South Fence to purchase another Okuma; the second new machine in the space of a year.

“We have an Okuma that is a good 20 years old,” says Mr Neill of the MX55VB. “It still works well but with more business we needed more flexibility so about 12 months ago we bought an Okuma M560V-R machining centre.”

The older machine gives as good as it gets, but the pair agree that the new unit has brought significant improvements in speed, functionality and performance.

The follow on post sale, as mentioned, is vital for the well-oiled business to keep the cogs of progress in motion. With Okuma still able to supply many parts for its older machines, Mr Neill and Mr Byers know that even their machinery purchases of up to 28 years ago have plenty of life left in them yet.

All machinery is fully supported with the very latest cad-cam technology ensuring the very best of Kiwi machinery can be seen on the world and local stage.

The post South Fence Machinery: Wired for Success appeared first on NZ Engineering News.

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