DISTRIBUTION


enables engineers to react rapidly to changes in a component’s condition. The most common type of vibration sensors are accelerometers, with strain gauges and microphone sensors also being widely used.


This ability to monitor vibration from afar has proven to be a great cost and time saver, with maintenance costs down by 50%, unexpected failures reduced by 55%, and repair and overhaul time cut by 60%. This is due largely to the fact that a lot of programming and testing can now be done remotely, which eliminates a sizable portion of the physical travel previously required, as well as the need for human beings to enter areas that could potentially be hazardous. Moreover, devices can be set and left in place, so test engineers and design engineers don’t have to constantly monitor voltages or temperatures on site. It can all be done portably, wirelessly and with high accuracy. Remote and automated monitoring also substantially reduces human error.


Finally, improved reliability also means that fewer spare parts, with the additional costs of storing and maintaining them, need to be kept on site.


Long range monitoring gives faster data capture


Capturing production and performance data is increasingly important to the smooth running of a plant and the ability to access this data or measure conditions from a distance is a great advantage. With long range data transfer abilities, sensors can


be placed at almost any distance from the device they are monitoring, while also consuming much less power. Another requirement for maintenance departments is easy and rapid assessment of machine and pipe conditions to identify gas leaks or hot spots that may indicate an imminent issue.


A typical assessment device is the Fluke PTi120 pocket thermal imager, used to quickly scan electrical equipment, pumps, motors, HVAC and process control equipment for hot and cold spots that can indicate possible failures. Many handheld devices, such as those from Fluke, now include wireless connectivity, enabling users to easily connect with PCs and portable devices, such as iPhones and iPads, and share data and images with other maintenance staff. Automation can also capture production data to automatically assign the correct number of workers to a particular line, making planning more efficient.


Adaptive manufacturing Another trend that cuts the risk of human error while making the best of human abilities is the booming deployment of collaborative robots, more commonly known as ‘cobots’. By working safely alongside robotics in a highly controlled environment, people can do what they are good at, i.e., analysis and problem solving, while the robots do the repetitive, dull or risky tasks. The highest level of collaboration is for the robot and human to co-operatively share workspaces and tasks. This is especially useful in small parts assembly lines.


Easier programming and set up are now possible through block-based software and simulations. These allow the setup of a robot to be finalised before it starts operations, bringing robotic automation within reach of many more companies. End effectors are also becoming more capable and sophisticated, enabling even delicate items such as fruit and flowers to be handled without damage, thus reducing wastage. Production costs and lead times can also be reduced by 3D printing. If a manufacturer needs a small part to keep a production line operating, it can use 3D printing to make the part it needs. This saves downtime while also avoiding the cost and delay of ordering the part or carrying stock of it on site. An example of such professional 3D printers is the ULTIMAKER S7, which can print in a wide range of materials, including carbon fibre, glass, metal and wood composites. This versatility makes it suitable for a wide range of part-production tasks. With robots, these highly adaptive technologies deliver the power to produce many more different types of products without requiring excessive downtime. Although none of the factors above will in isolation have a huge effect on the efficiency of a factory, combining the use of digital data and controls, robotics and sensor-enabled production tools means that small gains can quickly add up to big savings. The net result is that manufacturers can produce electronic equipment that is more reliable, higher quality and more cost-competitive, helping build sustainable success across a vast range of industries.


MARCH 2024 | ELECTRONICS FOR ENGINEERS


21


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54