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Ford South Africa Introduces New Diesel Engine Assembly Line

This is only the second diesel engine to be introduced at the Port Elizabeth plant since opening its doors in 1964, and will be built alongside the current Duratorq TDCi four and five-cylinder diesel engines as used in the existing Ford Ranger and Everest models.

The new assembly line is located in a totally revamped 3 868 m2 section of the Struandale Engine Plant, and boasts the latest Ford technologies.

“Our new engine assembly line represents Ford’s latest, state-of-the-art manufacturing processes that guarantee the highest standards of workmanship, product quality and performance,” explains John Cameron, Plant Manager of the Ford Struandale Engine Plant.

“We invested in a sophisticated sub-assembly area for the cylinder head, incorporating four automated robotic stations which ensure maximum precision in the fitment of parts.

Throughout the line we have extensive errorproofing and traceability mechanisms in place with multiple camera and transponder systems,” Cameron says.

In addition, there are two cold-test cells at the end of the assembly line to check operating parameters and pressures, followed by a hot-test cell that evaluates the integrity and performance of the engine in normal running conditions. There is also a brand new engine dynamometer located at the plant to  conduct a wide range of performance and durability tests.

Eight derivatives of this engine will be assembled at the Struandale Engine Plant when production officially commences in the fourth quarter of 2018. Its most noteworthy application will be in the thrilling new Ford Ranger Raptor, which will be produced at Ford’s Silverton Assembly Plant in Pretoria for local release in 2019. Additional models set to receive this new diesel engine will be announced in due course.

The new assembly line has an installed capacity of 120 000 engines per annum, although the volumes will be significantly lower during the start-up phase, beginning with a single shift comprising 85 employees dedicated to this line. The assembly crew is drawn from Ford’s existing employees, who have undergone extensive training during the build-up phase over the past year, both at supplier companies overseas, and within the Struandale Engine Plant’s on-site training centre.

Strong Growth On Global Commercial Vehicle Market

The global market for heavy-duty commercial vehicles over 6 tonnes grew strongly in 2017. A good 3.3 million trucks were sold worldwide, which was a rise of 16 percent compared with 2016.

Matthias Wissmann, President of the German Association of the Automotive Industry (VDA), stressed, “this growth was driven by the keen demand in China, but also by the markets in Europe and the US and the growth in India. In addition, Brazil and Russia returned to the growth zone – in time for this year’s IAA Commercial Vehicles.” The IAA Commercial Vehicles 2018 will take place in Hannover from September 20 to 27, and is organized by the VDA.

Worldwide, four out of ten heavy-duty commercial vehicles were purchased in China. This took the Chinese market to a volume of 1.35 million vehicles. The year-on-year growth of 40 percent equates to 384,000 units. The robust market development was principally due to the purchases brought forward before the nationwide introduction of China’s new exhaust standard 5 in mid-year and to stricter controls to prevent overloading and the extra heavy trucks needed in their wake. In India, too, sales of heavy commercial vehicles increased markedly in 2017. The market expanded by 13 percent to reach 295,000 trucks.

After two years of double-digit growth, new registrations in Western Europe added 2 percent last year, climbing to 291,000 heavyduty commercial vehicles. This is the highest level since 2008. Among the large volume markets, the strongest growth rates were seen in Italy (+8 percent) and France (+7 percent). While the German market slightly exceeded its 2016 result (+0.3 percent), the Spanish market contracted minimally (-0.4 percent). The market in the United Kingdom lost rather more ground (-3 percent); despite positive developments in the first half-year, the final result moved further and further away from the previous year’s level.

The US truck market picked up a lot of speed in the second half of 2017 and made up for losses at the beginning of 2017. The market finished the year with growth of 4 percent, on 415,000 heavy trucks sold. The heavy-duty segment over 15 tonnes ultimately proved to be the most dynamic.

Last year, the Brazilian truck market began consolidation at a low level. Following three years of double-digit contraction, new registrations increased by 3 percent to 48,000 units. However, this is still less than one third of the record level from 2011. Recovery was much speedier on the Russian market for heavy-duty commercial vehicles, which had also sustained marked losses in recent years, and here sales added nearly 50%.

Rising industrial production and economic confidence ahead of IMTS 2018

Numerous major economic indicators signal that the U.S. manufacturing industry, the second largest market in the world with a value of nearly $9 trillion, will enjoy its strongest growth in more than a decade leading up to IMTS 2018, held Sept. 10-15, 2018 at McCormick Place in Chicago.

Overall manufacturing growth for 2018 is expected to increase by 8 to 9 percent compared to 2017, according to Patrick McGibbon, Vice President of Strategic Analytics, AMT – The Association For Manufacturing Technology, which produces IMTS.

“Economic indicators suggest a longer term, continued expansion. In the short term, we anticipate immediate acceleration in capital investment among IMTS 2018 visitor and exhibitor companies,” says McGibbon. “Changes to the U.S. tax law should further encourage purchasing during and after the show. Reduced tax rates will increase available capital. R&D tax credits expand innovation and fully expense capital expenditures which encourages purchasing.”

“The U.S. manufacturing sector is expressing economic confidence at levels not seen since the dot com boom. If there was ever a year to experience the energy, optimism and innovations offered at IMTS, this is it,” says Peter R. Eelman, Vice President – Exhibitions & Business Development at AMT, who has participated in every IMTS since 1980.

Orders for manufacturing technology in January 2018 were up 44 percent compared to January 2017, according to the latest U.S. Manufacturing Technology Orders (USMTO) report from AMT. It was the second-largest January in the 22 years recorded by AMT’s USMTO program.

The February 2018 Manufacturing ISM® Report On Business® notes that the PMI® (Purchasing Managers Index) registered 60.8 percent, an increase of 1.7 percentage points from the January reading of 59.1 percent and the 18th consecutive month of expansion. A reading above 50 percent indicates the manufacturing economy is generally expanding.

Other positive indicators include U.S. cutting tool shipments, a metric produced by the U.S. Cutting Tool Institute (USCTI) and AMT. With a year-to-date total of $2.195 billion, cutting tool shipments for 2017 was up 8.3 percent over 2016. The Michigan Consumer Confidence Index rose to 120 in March, the highest level in over 14 years.

Industry capacity utilization stands at 78 percent and is headed toward 80 percent, which economists consider a key metric that signals full utilization. At this point, supply chain and labor constraints can hinder further expansion. Some of the strongest U.S. segments include automotive (82.9 percent capacity utilization), aerospace (77.6 percent) and energy and power generation (79.8 percent) segments.

“Growth-minded visitors will attend IMTS 2018 looking for solutions that remove production bottlenecks,” says Eelman. “For many manufacturers, simply doing more of the same thing in a larger space or adding more people isn’t a viable option. Growth requires change and visitors view IMTS as a change agent. They come to the show knowing that they can find technologies that not just shave minutes off production cycles, but that can positively disrupt their manufacturing approach.”

As of March, more than 1,800 exhibitors have secured more than 1.3 million sq. ft. of exhibit space.

Airbus And Human Spaceflight – From ATV To Orion

Ten years as prime contractor for ESA – it’s just the beginning for Airbus in human spaceflight: The successful mission of the first Airbus-built ATV (Automated Transfer Vehicle) Jules Verne, launched on 9 March 2008, has become a key element of pioneering technologies for human spaceflight that includes Spacelab, the ATVs and the Columbus module of the International Space Station (ISS).

Together they pave the way to the Orion European Service Module (ESM), Europe’s latest contribution to human spaceflight developed by Airbus, again as prime contractor.

NASA’s Orion spaceship is designed to take humans to the Moon and beyond, with the possibility of even reaching an asteroid and maybe Mars in the 2030s. The ESM integral to the crew module is designed to supply power, propulsion, thermal control, water and air for future human deep-space missions.

Ten days after launch, the first ATV, the sophisticated space freighter executed a perfect manoeuvre to dock automatically with the ISS. The ATV then not only delivered vital supplies to the ISS but also successfully carried out its orbit-raising mission and became an integral part of the ISS. After six months docked to the ISS, the first ATV Jules Verne detached on 5 September 2008 and began its last journey in Space, which ended with a controlled burn up on re-entry into the Earth’s atmosphere on 29 September 2008. Four more ATVs (2011–2014) were sent to the ISS. Airbus was prime contractor to the European Space Agency (ESA) to developand build all the ATVs and prepare their missions to the ISS.

In total the ATVs shipped more than 31.5 tonnes of supplies to the ISS until 2015. They boosted the Space Station to raise its orbit numerous times and helped manoeuvre it out of the way of space debris. The ATVs demonstrated the ability to dock automatically with the ISS, which is vital technology for future space exploration missions. Airbus achieved this as part of a European partnership and thanks to the ATVs’ outstanding performance, the company became a full partner of NASA for major space programmes.

“Spacelab, Columbus and the ATVs have fully proved our capabilities to develop a highly reliable system that will play an integral part in the success of NASA’s future exploration missions: namely the European Service Module of the Orion Multi-Purpose Crew Vehicle,” said Nicolas Chamussy, Head of Space Systems at Airbus.

The ESM is cylindrical in shape and about four meters in diameter and height. It has four-wing solar arrays (19 meters across when unfurled) like the ATVs. The solar arrays are based on Airbus’ flight proven technology which are also installed on their highly reliable geostationary telecommunication satellites which operate for a minimum of 15 years in Space.

The ESM’s 8.6 tonnes of propellant will power one main engine and 32 smaller thrusters used to perform orbiting manoeuvres and attitude control. Once again, ESA will rely on the experience gained with the ATVs, which successfully used their thrusters to allow the ISS to evade space debris.

“The requirements for a mission to the Moon are of course very different to those for travel to the ISS in low Earth orbit. But the clever design of the ATV has allowed us to evolve the concept for new missions, for example by integrating one large main engine providing enough power to fly to the Moon and back,” said Nicolas Chamussy.

In 2019 / 2020, the Orion capsule will perform an uncrewed mission known as Exploration Mission-1, with the aim of travelling 64,000 kilometers beyond the Moon to demonstrate the spacecraft’s performance. The first human spaceflight mission, Exploration Mission-2, is expected to launch four astronauts on board Orion in 2023.

Indian Demand For New Aircraft Forecasted At 1,750 Over 20 Years

India will require 1,750 new passenger and cargo aircraft over the next 20 years to meet an exponential rise in both passenger and freight traffic, according to Airbus’ latest India Market Forecast.

To help meet this growth, India will need 1,320 new singleaisle aircraft and 430 widebody aircraft valued at US$255 billion.

While much of the air traffic growth is expected to be driven by the fast expanding economy, rising wealth and urbanization, ambitious government-backed regional connectivity programmes are also set to enhance demand for air travel. By 2036, Indians will each make four times as many flights as today. As a result, traffic serving the Indian market is forecast to grow 8.1 percent per year over the next 20 years, almost twice as fast as the world average of 4.4 percent.

Domestic Indian traffic is expected to grow five-and-half times over the next 20 years (2017–2036) reaching the same level as U.S. domestic traffic today, making it one of the world’s fastest growing markets, according to Airbus’ latest India Market Forecast for the period.

“Make in India is at the heart of our strategy. Airbus has the largest footprint in India of any international aircraft manufacturer, nationwide across all aircraft programmes. Our sourcing volume has grown 16 times over the past 10 years and it is currently at more than US$550 million annually,” said Srinivasan Dwarakanath, President – Airbus Commercial Aircraft in India.

India is set to become the world’s third-largest aviation market by 2019/2020 and Airbus is well positioned to partner its growth with backlog orders of over 530 aircraft to date.

SAMI And Boeing Joint Venture

Saudi Arabian Military Industries (SAMI) and Boeing recently signed a Memorandum of Agreement (MoA) to develop a new joint venture (JV) aiming to localize more than 55% of the MRO services for fixed and rotary-wing military aircraft in Saudi Arabia.

The agreement will also transfer technology to install weaponry on these aircraft as well as localize the supply chain for spare parts in the Kingdom.

The signing ceremony came in conjunction with HRH Prince Mohammed bin Salman’s visit to Seattle, which included an official visit and tour of Boeing’s aircraft manufacturing facilities. The agreement was signed by H.E. Ahmed Al-Khateeb, Chairman of SAMI, and Dennis Muilenburg, Chairman, President and CEO of Boeing, at Boeing’s commercial manufacturing facility in Everett, Washington.

The joint venture agreement will provide sustainment services for fixed- and rotary-wing military aircraft of the KSA military fleet and will be the sole provider of these services for all military aviation platforms of the KSA military fleet, strengthening the Kingdom’s defence capabilities and enhancing its deterrent potential.

The MoA will further solidify the relationship between Boeing and Saudi Arabia and result in the development of local research, design, engineering, manufacturing and MRO abilities. The JV will improve performance and growth, upgrade readiness of and increase confidence in the Saudi military fleet, while enhancing maintenance capabilities and reducing support costs throughout the fleet’s life. In addition, the agreement will create 6,000 jobs and training opportunities for Saudi youth.

Boeing Recognized By Guinness World Records For 10,000th 737

Thousands of Boeing employees gathered at the company’s Renton, Wash. factory recently to celebrate the 10,000th 737 to come off the production line.

With this airplane, a 737 MAX 8 for Southwest Airlines, the 737 has broken the GUINNESS WORLD RECORDS title for the most produced commercial jet aircraft model.

“This incredible milestone is a testament to the work we do every day to build the most reliable and efficient single-aisle airplane in the world,” said Boeing Commercial Airplanes president and CEO Kevin McAllister. “It represents more than 50 years of success and achievement on the part of thousands of Boeing employees past and present, our supplier partners, and our airline customers around the globe who put their confidence in the 737.”

The 737 previously held this GUINNESS WORLD RECORDS title in 2006 for the 5,000th airplane to come out of the Renton factory, a mark that took almost four decades to reach. Due to growing market demand and higher production rates, the 737 program reached the 10,000th airplane milestone only 12 years later.

“The speed at which Boeing achieved this new milestone is very impressive,” said Michael Empric, official adjudicator for GUINNESS WORLD RECORDS. “We are excited to once again recognize the 737 and the important role it plays in commercial aviation.”

Boeing will increase 737 production from the current rate of 47 airplanes per month to 52 airplanes per month later this year. The 737 program has more than 4,600 airplanes still on order fueled by sales of the newest version of the 737, the 737 MAX.

Laser Technology: Bystronic’s Bystar Fiber Laser And Bytrans Loader

 

Bystronic – a world-leading provider of cutting and bending solutions – offers the steel industry the ultimate in productivity solutions.

By linking its flagship ByStar 10kW fiber laser to a ByTrans loader, it is now possible to automate production to a far greater level than was possible previously.

Bystronic’s 10kW ByStar Fiber laser, introduced at Euroblech in 2016, is to date Bystronic’s most powerful laser on the market. The ByStar Fiber’s new cutting head will deliver the highest part output through the full spectrum of sheet thicknesses, from thin gauge up to 30mm with an impressive part accuracy. It will also cut other exotic materials such as aluminium, brass and copper without the need for deburring. In terms of productivity, the ByStar Fiber is up to five times faster than a 4kW CO2 laser.

Even compared to a 6kW fiber laser, the time to complete a job on 6mm steel could be cut in half and the cost per part reduced by as much as 35%.

As the ByStar was designed from the ground up to be the most productive fiber laser on the market, it incorporates a number of other ground breaking design features. A newly developed ultra-fast bridge frame which is more torsionally rigid, gives greater accuracy and better edge quality. Bystronic’s detection eye technology identifies the edge of the sheet in six seconds, allowing cutting right up to the edge of the sheet with great accuracy. This significantly reduces a fabricator’s scrap rate.

However, the ByStar’s remarkable new levels of productivity could it be diluted if the loading and unloading of the machine are not able to match its superior production rate. To maximise the ByStar’s productivity potential, Bystronic therefore developed a range of loading and unloading automation solutions. Notable among these, the ByTrans Extended loaders are linked to the ByStar and will automatically load sheets onto the laser’s shuttle table. After the cutting cycle is completed, they are able to unload finished parts and residual sheets.

The ByTrans requires only 60 seconds in which to carry out the complete loading and unloading cycle. This means that the automation system is always faster than the cutting plan that is being processed. For fabricators or manufacturers, this means that the laser can cut uninterrupted for an extensive period of time. While the ByTrans loads one shuttle table, the fiber laser is cutting components from the raw material on an alternate table.

The ByTrans and the ByTrans Extended are operated using the ByVision touch screen. Bystronic has seamlessly integrated the control of the two automation systems into the laser’s operating software, which enables users to perform all the operating steps on a single touch screen.

The development of these automation technologies is part of Bystronic’s overarching aim to provide its customers with unsurpassed productivity solutions, ultimately leading to greater profitability.

For more information, contact First Cut – Tel: 011 614 1112

Laser Technology: AMADA LCG-3015 AJ – Perfect Balance Of Low Energy Usage And High Speed Productivity

The new 9kW version of the AMADA LCG- 3015AJ Laser allows high speed and top quality laser cutting also of medium thickness materials, while providing a quality cut never previously achieved by a fiber laser.

Three 3-kW fiber laser modules form the basis for the 9kW version of the AMADA LCG-AJ laser cutting system.

The AMADA LCG-AJ completes the range of proven AMADA fiber laser systems for the high performance segment. The high output permits very high speed and top level quality processing of thin and midthickness materials. However, the system also supports the precise, reliable processing ofexceptionally thick sheets where the cutting speeds of mid thickness mild steel is 1 and 2 times faster than the 6kW. Furthermore, the high power fiber laser makes it possible to process various thick materials with quality results.

Latest generation of laser modules

AMADA was the world’s first laser manufacturer to develop its own fiber laser oscillator. In a CO2 laser oscillator, laser light is pumped with laser-gas, emitted via the output mirror and delivered by reflector mirrors to the cutting head. The fiber laser oscillator has no need for this. The monolithic structure allows the laser power produced by the individual laser diode banks to be combined into a single fiber optic cable for direct delivery to the cutting head.

In order to enhance the production of fiber laser oscillators at AMADA’s Fujinomiya facility and to meet ever increasing demand, clean rooms have been created specifically for production and assembly operations.

Alternative to the CO2 Laser

The AMADA LCG-3015AJ 9kW can be regarded as an appropriate, high performance alternative to CO2 lasers. It excels in terms of energy consumption: Although the output power has increased by a third compared to the 6kW laser, the energy consumption of the 9kW version is not significantly higher. By contrast, a similar increase in power in a CO2 laser would require significantly higher consumption levels. Another advantage: The AMADA fiber laser has a modular structure and its short wavelength means that there is no need for a deflecting mirror. Efficiency can be increased further through automation options such as the MPL (Sheet manipulator), the ASF (Sheet storage and manipulation) and even the TK system for individual part removal.

Machines are available in 2kW, 3kW, 4kW, 6kW and 9kW options.

For more information, contact Amada – Tel: 011 453 5459

Laser Technology: Platino Fiber Evo

Platino Fiber Evo is equipped with fiber laser sources (with 2, 3, 4, and 6 kW power) that provide the customer with high performance and, at the same time, great reliability.

One of the major innovations introduced is a new head for fiber laser cutting, which ensures significant benefits for the customer in terms of machine reliability, increased performance for reduced piercing times and increased cutting speeds, especially on thick material. Also, the new Platino Fiber Evo cabins increase the machine accessibility, reduce its overall dimensions and are easy to install. This version also features a new generation control, “Open”, produced by Prima Electro, that allows easy and complete management of the work programming and machine parameters.

In line with Prima Power tradition, the Platino Fiber Evo has been developed to maximize the customers’ competitiveness according to their applications. In fact, the machine is provided with different packages of options dedicated to the various production needs: Smart Cut, Max Cut and Night Cut.

New Head With Integrated Adaptive Collimator

The main innovation concerns the technological hub of laser machines, the cutting head. Platino Fiber Evo is equipped with the new cutting head with adaptive collimator designed and manufactured by Prima Power. It is a fiber laser cutting head with adaptive optics for automatic management of the focus position and focus radius diameter. Thanks to a quick, reactive and precise stand-off measurement, the new head is designed for excellent quality and dynamic cutting on all materials, but also for using maximum cutting pressures and resisting the most demanding environments. In line with Prima Power’s tradition, process reliability still provides important benefits thanks to the SIPS (Safe Impact Protection System), the lens case equipped with OPC (Optical Precision Control) quick alignment system and protection window case for easy inspection.

The head is equipped with a single focus lens, suitable for all production needs. The protection window is integrated into a dedicated case for easier inspection. The automatic adjustment of the focal position and the beam diameter provides excellent cutting flexibility of various thicknesses without manual intervention by the operator, ensuring maximum productivity.

The OPC (Optical Precision Control) can diagnose any differences between the real position and the theoretical position of the focusing beam and show them on the graphical user interface of the control system. Two knobs located at the front of the cutting head can be used to perform corrections that may be needed to center the lens in virtually no time.

A capacitive sensor keeps the distance between the nozzle and the sheet constant. The system is also equipped with a nozzle calibration and cleaning kit. After executing a predetermined number of holes or machined parts, the machine will automatically clean the nozzles and perform the sensor calibration cycle.

This translates to the customer in improved cutting performance, especially on thicker materials, reduced piercing times, and increased reliability of the entire machine.

New cabins

Another important new feature relates to the two new cabins available for Platino Fiber Evo, Lean and Open, which have been successfully introduced on the Laser Genius, another Prima Power 2D laser cutting machine. The Lean cabin is the best solution in terms of compactness, cost and easy installation.

With the Open cabin it is possible to utilize the good accessibility provided by cantilever structure of the machine. This cabin allows front, lateral and roof opening. The two lateral sliding doors can be completely opened to ensure excellent accessibility for the operator and allow easy loading and unloading of 1500 x 3000 mm sheets in any configuration, including automation. Next to the numerical control there is a manual opening sliding door that allows the operator to access the work area for lens replacement and routine maintenance operations.

New Open CNC Numerical Control

Platino Fiber Evo features the latest generation numeric control designed and manufactured by Prima Electro, a company of the Prima Industrie Group. It represents the intelligent and easy-to-use motor of Prima Power machines and provides the basic information to manage and monitor production. Its main functions include laser parameters monitoring and management, work programs editing and programming management with a complete preview function, also available in real time.

Dedicated Options For Every Production Need

The Smart Cut options suite is the ideal solution for fast processing of thin sheet metal (up to 6 mm thick) for which the nitrogen cutting technology can be used: a result obtained through technological solutions such as Smart Moves or Grid Cutting, which reduces unproductive times, such as the head positioning times. The result is a dramatic reduction in cycle times up to 30%.

To maximize productivity on parts made of medium and high thickness sheets (6 to 25 mm), the Max Cut options package was created. It is the integration of a customized database and of a series of technological options, achieved after many years of experience in the field of laser applications. It allows 40% cycle times reduction and a surprising 90% reduction of piercing time.

In case of intensive production, Prima Power has developed the Night Cut options package, which maximizes productivity and provides better process monitoring. This is made possible by devices that control the machining process status and intervene in case of errors restarting the operation or informing the operator remotely. The LPM (Laser Piercing Monitor) controls the piercing operations, the Plasma and TipTouch Restart monitor the cut, while the email Dispatching prompts the operator in case of problems.

For more information, contact Talmac Machine Tools – Tel: 011 827 6539

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