Features

Maximum speed and detection rates of preferably 100 percent – these are the requirements for quality control in the packaging industry. The company INNDEO shows how these high requirements can be achieved with a sophisticated automation solution based on machine vision and deep learning technologies.

INNDEO, headquartered in Zaragoza, Spain, offers high-quality machine vision solutions for the automation of quality inspections with its INSPECTRA brand. Founded in 2016, the company has so far mainly been active in the food industry with its solutions and would like to gain a foothold in logistics in the future. For this purpose, the company has developed the Thermoseal & Label Inspector solution, which can be used to reliably inspect packaging and read labels. The device combines a wide range of equipment sophisticated technologies such as high speed and processing capture with INSPECTRA HSP® technology, hyperspectral vision, deep learning, and high- performance RGB.

Automating packaging inspection from end to end

INSPECTRA’s goal was to develop an end-to-end automated solution for the packaging industry. The advantages offered by such a solution based on machine vision are: Higher detection rates of packaging defects, cost savings, as well as the comprehensive digitalization of production processes in order to be able to monitor and improve them. In practice, many companies’ employees still carry out the inspection process manually. In this process, defects are often not seen by the human eye. As a result, defective products enter the supply chain and end up with the end customer. The goal of an automated solution must therefore be to reliably detect all conceivable defects in packaging. These include, for example, anomalies in the sealed or heat-sealed area, in the tray, in the inner product, in the film, or in the labeling. Furthermore, 100 percent automation of quality control reduces costs on the one hand and introduces objective criteria for sorting the products to be inspected on the other. In addition, quality and production data can be continuously digitized and the corresponding indicators displayed in real time.

Although the market offers several other machine vision devices and solutions, these often prove to be not robust enough, low performance, and difficult to adapt to changes in production lines. Due to a lack of precision and reliability in defect detection, many users refrain from using such solutions and prefer to perform defect inspection manually. INSPECTRA wants to eliminate exactly these deficiencies with its machine vision solutions: “In order to ensure faster inspection processes and more robust detection results than our competitors, we had defined a clear goal. For example, quality defects in food packaging were to be identified at a high production rate of up to two packs per second. This should enable inline rejection, which requires processing times of only a few milliseconds per image,” explains Emilio de la Red Bellvis, Chief Innovation Officer at INNDEO. To achieve these goals, it was essential to automate the application end-to-end using machine vision.  

Defect detection via machine vision

So, what does the setup of the Thermoseal & Label Inspector look like in concrete terms? Cameras positioned at various inspection points take images of the objects. These are processed by the integrated machine vision software MVTec HALCON. HALCON is the comprehensive standard software for machine vision, developed by MVTec Software GmbH, based in Munich.

There are different procedures for the various applications. For example, for sealed area inspection, HALCON determines the relevant area (Region of Interest/ROI) of the image for inspection based on various parameters. For this purpose, INNDEO uses high-resolution RGB vision technology for the simplest sealed area defects, such as a piece of ham, as its color is easily distinguishable in a transparent tray. In addition, the company uses hyperspectral vision technology for more complex defects. For example, melted ham fat in the same shade as the plastic of the tray or defects in opaque or printed trays can be detected.

Deep learning, which is a method in artificial intelligence (AI), is also used to detect certain defects. Through deep learning, the software attempts to simulate the behavior of the human brain and is able to interpret the images with a higher detection speed and efficiency than the human eye. The system is able to learn through a training phase, without the need for any additional programming by the user. This technology allows the detection of wrinkles in sealing films, faults in the arrangement of the product in the tray, and the detection of quality defects that cannot be distinguished by standard machine vision algorithms.

Another application scenario is the inspection of the labeling. To detect the label, a corresponding configurable tool looks for a specific pattern. Once this is located, the inspection processes take place. To do this, the application uses the optical character recognition technologies integrated in HALCON, such as OCR (Optical Character Recognition) or Deep OCR. Deep OCR uses a holistic deep-learning-based approach and is able to find and read text in the most difficult conditions, such as characters that are too close together, blurred, or incomplete. This allows various types of label inspection to be conveniently configured. Deep learning technologies and pattern matching of color tones are also used to detect anomalies in the applied labeling, such as wrinkles, creases, or tears, and contaminants such as feathers, hair, or bone traces.

Flexibility in interface integration

For the end customer, it is important that the Thermoseal & Label Inspector can also be seamlessly integrated technically into the existing process environment. This allows the user, for example, to control the inspection system in the environment that is familiar to him. “The integration of an interface was one of the biggest challenges during the implementation. This is because the various parameters of the inspection can be configured from another system control and all the images from the various cameras have to be analyzed in a very short time. It is also important not to forget that the image acquisition devices operate at enormously high speeds. So, the machine vision software has to decide in a very short time whether a package is faulty and has to be rejected,” explains Emilio de la Red Bellvis. Consequently, a lot of programming and debugging work was needed to distribute the entire processing load among the different threads of the microprocessor. In addition, computational operations with high loads – especially those using deep learning – had to be transferred to the computer’s graphics processing unit (GPU). The integration of the solution was simplified by the possibilities offered by MVTec HALCON: “The software offers various interfaces for many types of industrial cameras and the possibility to directly run scripts within a real application using the HdevEngine and debug it. We see the wide variety of image processing algorithms, convenient programming, and seamless integration with our software as further strengths of MVTec products,” confirms Emilio de la Red Bellvis.

On the hardware side, the application setup includes various components such as several latest-generation industrial PCs. These receive the images from the individual cameras and communicate with programmable logic controllers (PLCs). In the process, Emilio de la Red Bellvis faced another challenge: “Given the current shortage of electronic components, we had to develop flexible programming. This allowed us to accommodate different camera types, processing architectures, and GPUs so that the hardware could vary depending on availability.”

Award for most innovative technology

As a result, INSPECTRA has been able to solve all the problems that producers have to face with its Thermoseal & Label Inspector inspection solution by integrating the machine vision software MVTec HALCON. In this way, the quality defects on the packaging as well as on the product itself are avoided. Therefore, costs for the destruction, replacement, and transport of defective products are eliminated. In addition, producers can guarantee their brand promise to consumers at all times due to the reliable and consistent quality. The biggest advantage, however, is that the quality control can be automated end-to-end along the entire production process. This reduces the labor costs incurred for quality assurance, lowers the error rate, and eliminates the subjectivity of the inspection criteria. Last but not least, the technology can detect defects that would have been hidden from the human eye. 

“We can be very satisfied with our work because we have overcome the challenges. We are currently in contact with many customers from the food industry who are interested in our products. At the Meat Attraction 2022 trade show, the Thermoseal & Label Inspector even received an award as the most innovative technology for the ancillary industries of the meat industry. The inspection solution was ultimately a result of the interaction of MVTec HALCON with our hardware and optimized INSPECTRA software architecture. Thus, our years of research and development work have fully paid off,” Emilio de la Red Bellvis sums up.

Effective monitoring of turbines including overspeed protection in the power generation industry is critical to ensure smooth running and trouble-free operation, especially in today’s highly competitive and energy cost–conscious environment. Failure of the turbine, or pump speed governing system can lead to rotor damage with expensive consequences. Independent speed monitoring and protection is essential to minimise these risks and the SENTRY G3 machine protection system developed by condition monitoring specialists, SENSONICS has provided high-integrity overspeed protection across a wide range of power generation applications for over 20 years.

A good example of this is at the National Gas Transmission (Previously National Grid) site at Huntingdon Compressor Station, part of the UK’s National Transmission System (NTS). This is one site within a network of pipelines which supplies gas from natural gas terminals situated on UK coastlines to around 40 UK power stations and other large industrial users as well as commercial and domestic customers. The compressors at the Huntingdon site help to maintain and boost gas pressures flows to the South and South West of the UK. The site currently has three operational gas compression units covering the Power Turbine System and Gas Turbine Starter System.

Sensonics supplied two Sentry G3 Overspeed Protection Systems with 2 out of 3 voting capability, with certification to IEC 61508 functional safety level SIL 3, to the Huntingdon Compressor Station. These were installed in January 2023, replacing existing obsolete equipment which had been deemed to be ‘end of life’ and in ‘fault condition’. After 10 months of operation, Ray Woolmer, Control & Instrumentation Engineer, part of the Rotating Machinery Support Team, confirmed, “The new Sentry G3 rack was an available and fully compliant solution with the same footprint as the original equipment, removing the need for additional modifications”. He confirmed, “The Sentry G3 units were fully compliant systems, providing reliability and simplicity of use and features such as local channel status displays on each module provides us with quick and easy status checks”.   

Looking ahead, Ray appreciates that Sentry G3 units have the important ability to be repurposed for the ongoing research and development of a future grid Hydrogen Network and so assists them in ensuring compliance for the additional safety requirements of a Hydrogen network.

Since its introduction over 20 years ago, the design of the Sentry G3 system and its features have been developed and enhanced in conjunction with customers’ needs in both the conventional and nuclear power industry, resulting in a highly reliable hardware configuration with online test facilities. For example, the provision of gas turbine specific measurements such as first order vibration tracking and dynamic pressure which are both requirements recommended by gas turbine manufacturers.  In addition, the speed algorithm has also been optimised to accept a wider range of speed probes and now offers a market leading sensitivity performance over a wide speed range ensuring the turbine interlocks can be integrated effectively to the G3 system over a range of operational conditions.

The new measurement algorithms can be downloaded in to the common hardware module and complement the other established measurements such as broadband vibration, temperature and speed.  The flexibility of the G3 system sensor interface also permits a wide range of sensor types to be utilised providing both the necessary drive power supplies and fault detection.

The system offers excellent channel density with up to 24 measurement channels in a 3U x 19” racking format, while the diverse system architecture separates functions across the independent modules providing a channel reliability suitable for safety instrumented systems.

In summary, Sentry G3 provides state-of-the-art protection for the following modes:

Measurement – Absolute bearing and relative shaft vibration, displacement and thrust position, speed, phase and reverse rotation, differential and casing expansion, rod drop and temperature.  

Turbine Specialist Measurement – Shaft eccentricity, order tracking, dynamic pressure and mark – space differential expansion.

The additional features incorporated into the latest Sentry G3 system ensures more than just machine protection, it provides a set of tools to assist plant engineers to optimise the control and overspeed management of turbines and other rotating plant.   

More at:  https://www.sensonics.co.uk/wp-content/uploads/2019/04/AB14-760R1.pdf 

Leading manufacturer of high-performance interconnect systems, Nicomatic is showcasing its high-reliability, space-proven modular interconnects – including its new FFCs for space: dense, lightweight flexible cables that ensure signal and power connection in all types of space applications – on stand D37 at Space-Comm Expo 2024, taking place from March 6 to 7, at Farnborough International Exhibition & Conference Centre in Farnborough, UK. 

A growing space powerhouse, with industry turnover of £17.5 billion in 2022, the UK contributes 6.5% to the global space market. The UK’s largest space industry event, Space-Comm Expo gathers space, aerospace & defence, and downstream & upstream industries for two days of high-level networking, exhibition, education and business, focused on the commercial future of space. Supported by key industry associations, Space-Comm Expo showcases developments in technology and the end-to-end supply chain for products, services and applications servicing commercial enterprises, Government and defence organisations. 

Harsh-environment electronic space systems demand highly specialised interconnect components to ensure peak technical performance and secure data transmission in the extreme conditions of space – including vacuum, radiation and dramatic temperature fluctuations. Nicomatic’s DMM, CMM and EMM Series connectors have all been specified in recent space applications, including the European Space Agency’s (ESA) ExoMars astrobiology programme to search for signs of past life on Mars (CMM connector in the ExoMars Orbiter), China’s space programme for exploration on the Moon (custom connector in the Jade Rabbit rover), the ESA-led JUICE space mission (CMM connector in JUICE’s mass spectrometer for the observation of Jupiter’s icy moons), and multiple other international space and satellite programmes. 

Dense, lightweight and designed to be folded or coiled, the new FFCs (flat flexible cables) for space not only deliver significant weight and space savings, but also overcome space industry challenges by integrating cables into complete interconnect solutions. Manufactured from NASA-grade materials to meet outgassing requirements, FFCs for space create strong board-to-board connections on PCBs and display boards in electronic equipment, systems and sub-assemblies, linking data and power points in tight areas. These lighter, more flexible interconnects ensure robust, reliable signal and power connection for electrical harnessing systems in satellites, exploration rovers, solar arrays, research orbiters, HD cameras, radar and satcomm systems, communication units, optical sensors and simulators.

DMM Series 2mm pitch low-profile metal connectors comply with MIL-DTL-83513G and enable a far wider choice of arrangements compared to other mil-spec connectors, such as Micro-D or Sub-D. Highly modular, contacts can be signal (LF), power (HP) or coax (HF), with up to 10 million arrangements for board-to-board, board-to-wire, wire-to-wire or panel mount. 

CMM Series 2mm pitch MIL-DTL-55302F connectors also offer signal, power and coax, with more than 20 million arrangements possible. They save up to 60% space and up to 50% weight compared with other connectors offering the same functionality. Shock-and-vibration-resistant, oxygen-free, radiation-resistant and able to withstand temperature cycling between -60°C and +260°C, CMM connectors are proven to withstand the rigours of space applications.

On a 1.27mm pitch, the MIL-DTL-83513 conformant EMM Series is more than 40% smaller than its parent CMM, or 20% compared to Micro-D. Key features include reversed contacts, integrated 90-degree back protection and interchangeable hardware. Again, extreme modularity is offered, with 4 to 60 signal contacts for board-to-board (thanks to secure wiping length) or board-to-wire configurations.

Highly experienced in solving the complex interconnect problems found in space projects, including creating custom solutions, Nicomatic engineers are available on stand D37 at Space-Comm Expo and throughout Nicomatic’s global network of offices.

Pickering Interfaces will showcase its range of industry-standard modular signal switching & simulation products for electronic test & verification – including fault insertion and sensor simulation modules for Hardware-in-the-Loop simulation, as well as RF & microwave switching up to 110 GHz – on stand D32 at Space-Comm Expo 2024, taking place from March 6 to 7, at Farnborough International Exhibition & Conference Centre in Farnborough, UK.

A growing space powerhouse with an industry turnover of £17.5 billion in 2022, the UK contributes 6.5% to the global space market. The UK’s largest space industry event, Space-Comm Expo gathers space, aerospace & defence, and downstream & upstream industries for two days of high-level networking, exhibition, education and business, focused on the commercial future of space. Supported by key industry associations, Space-Comm Expo showcases developments in technology and the end-to-end supply chain for products, services and applications servicing commercial enterprises, Government and defence organisations.

“At Pickering, we know that space industry electronics engineers have unique testing needs driven by requirements around long operating life, high reliability and hostile environmental conditions,” said Steve Edwards, Product Manager at Pickering. “Our modular products are based on familiar open industry standards that ensure long-term availability, shorten development time and ultimately speed time-to-market. With expert-level knowledge in architecting switching and simulation systems, we help our customers achieve their test objectives efficiently and deliver products with intuitive tools to enhance development teams’ design efforts and productivity. The result is scalable COTS test systems that can be optimised to meet their needs today and in the future.”

Pickering will showcase the following switching & simulation products, solutions and demos on stand D32 at Space-Comm Expo 2024:

• PXI/PXIe programmable precision resistor, RTD, thermocouple and LVDT/resolver modules for environmental sensor simulation
• Fault insertion modules that can be used to switch signals between simulations and real-life devices
• A 21-slot fully hybrid PXIe chassis and single-slot PXIe embedded controller
• The first modules in a new MEMS-based RF PXI & PXIe multiplexer family
• A configurable PXI microwave switch platform that allows RF test engineers to combine a wide range of high-performance relay types, while minimising chassis slot usage
• Turnkey LXI microwave switch & signal routing subsystems – including a custom 12×12 LXI microwave switching matrix demo

Pickering Interfaces stands behind its manufactured products with a standard three-year warranty and guaranteed long-term product support. For pricing and availability information, visit: www.pickeringtest.com

Almost everyone is aware of the electric vehicle (EV) revolution in the automotive industry. The switch from diesel and petrol engines to electric power is constantly in the news, and despite some obstacles to widespread adoption, the clock is ticking to a total switch by 2035. Here Gareth Tomkinson, Business Development Manager in Renishaw’s CMM & Gauging Products Division, explores the role of metrology in solving these challenges.

The global importance of reducing our reliance on fossil fuels has set the scene for the replacement of combustion engines with e-transportation. However, a snapshot of sales in 2023, showed EVs made up only 16 per cent of new car registrations in the UK, according to Zapmap. While they may be an increasingly common sight on the country’s roads, widespread adoption by the majority has yet to come.

Driving change

Whilst early EV adopters enjoy the benefits of a more peaceful, carbon friendly motoring experience, they are also learning to live with new issues like higher purchase prices, low battery range and lack of charging infrastructure. Across the world, governments, local authorities, large employers and manufacturers all have a part to play in providing improvements that encourage EV adoption as part of the overall drive to net zero.

Changing lane

Further upstream, manufacturers have switched some of their traditional powertrain lines, by removing the equipment used to machine cylinder heads, cylinder blocks, cranks etc. and replacing this with new processes for components like rotors and stators for electric motors. Although the electric motor is far from a new technology, the high efficiency versions required on such a mass scale do bring new engineering challenges. At this early stage in the evolutionary cycle of the ‘new’ electric motor, we see engineers applying their talents and producing a constant stream of incremental design improvements. However, each of these new designs must go from the CAD (Computer Aided Design) screen through a manufacturing process and end up as a finished product with the precise tolerances attributed to each part. This makes quality checks essential to ensuring efficiency, reliability and safety, especially important with new and relatively unproven designs.

These inspection checks are used by manufacturers in two distinct ways: Firstly, as a standard pass or fail quality check for individual components. Secondly, as a source of data that can be used to make constant micro-adjustments to upstream machining. Much like the small steering wheel adjustments we make to keep a car in between the white lines on a highway, these ‘process control’ adjustments help to nudge machining operations towards the ideal size and prevent drift towards out of tolerance limits.

Two-way traffic

Providing inspection solutions that cater to the changing needs of the automotive industry requires a two-way conversation. It’s almost impossible for manufacturers to predict exactly what new designs will arrive on their inspection table in the future. However, a flexible measurement system, such as Renishaw’s REVO® five-axis measurement head, is now available with a wide range of different sensors that can be tailored to future demands. These include rapid tactile scanning probes, non-contact camera-based sensors, a surface finish sensor and an ultrasonic thickness probe. Renishaw has worked closely with our customers to understand their unique requirements and match these to the systems we provide.

Down the road

As the manufacturing industries we serve evolve, so must we. As companies race to find better EV designs, inspection must not only be rapid and reliable, but flexible too. Improving the driving range of EVs means manufacturers must produce a range of prototypes with new components, experimenting with different materials and designs. Providing flexibility in the manufacturing inspection setup is increasingly important to help lines that are retooled or upgraded.

Flexibility is also important because even though the future currently looks likely to be heavily dominated by electric vehicles, manufacturers will offer a diverse range of propulsion technologies for the various niches of sustainable transport. Much like today’s mix of vehicles using petrol, diesel and LPG, each suitable to different applications, vehicles powered by eFuels, hydrogen and batteries might all have a place tomorrow.

When working on burgeoning technologies such as electric vehicles, it can be difficult to foresee revolutionary step-changes before they appear. Future predictions are also notoriously tricky to get right. By prioritising early discussions with customers, providers of metrology equipment can develop innovative and agile inspection solutions. Renishaw is providing inherently flexible technologies to meet its customers’ demands, helping to create more efficient, reliable and affordable EVs for a more sustainable future.

For further information on what Renishaw is doing for the automotive industry, visit www.renishaw.com

Global motion technology company Schaeffler announces the expansion of its operations in the U.S. with the addition of a new manufacturing facility focused on producing automotive electric mobility solutions. This announcement represents the company’s commitment to innovation and growth in the Americas region.

Schaeffler is investing over USD 230 million in building the new greenfield manufacturing facility, strategically located in Dover, Ohio, as well as future expansions in the state until 2032. As part of an agreement with the State of Ohio and JobsOhio, the company will receive incentives via grants and tax credits for these investments that will create 650 jobs in the state. These jobs will lead to growth at the company’s current facility in Wooster, Ohio, and the new manufacturing facility in Dover.

Construction of the new facility will begin in mid-2024 with an estimated completion in the third quarter of 2025. Once complete, the first phase of the facility will boast roughly 130,000 square feet of advanced manufacturing space dedicated to electric mobility solutions for the automotive industry. Products manufactured at this site will include electric axles for light and medium-duty vehicles.

“Our new plant will play a pivotal role in shaping our future in the Americas region,” said Marc McGrath, Chief Executive Officer of Schaeffler Americas. “Dedicated to advancing our innovative product offering, our new Dover, Ohio facility will feature state-of-the-art production processes so we can better serve our customers, while also adopting sustainable practices, as we continue to pioneer motion,” continued McGrath.

The new facility will produce products with cutting-edge technology, featuring Schaeffler-designed and manufactured tools and equipment. The products include electric axles, showcasing Schaeffler’s dedication to delivering sustainable and efficient high-performance solutions for the rapidly evolving electric vehicle market. Beyond innovation, sustainability is at the core of Schaeffler’s operations. The new facility will incorporate eco-friendly practices, aligning with the company’s commitment to environmental responsibility and to be climate neutral by 2040.

Serving the Dover Community – Committed to Ohio

The new manufacturing facility location is in the proximity of Schaeffler’s customers, major automotive OEMs, strategic suppliers, rail, access to highways and to the company’s Wooster facility, which specialises in the manufacturing of transmission systems and serves as an innovation hub for automotive electric mobility.

The new facility will create approximately 450 job opportunities by 2032. Positions include manufacturing operators (assembly, welding and CNC), material handlers, manufacturing leaders, engineers, maintenance technicians, tooling technicians, quality professionals and other support staff.

Schaeffler is committed to fostering innovation and expertise and investing in the next generation of manufacturing. Partnerships with local technical colleges will ensure a robust talent pipeline and provide the community both apprenticeship and pre-apprenticeship opportunities to be part of the future of electric mobility.

For more than 40 years, Schaeffler has considered the State of Ohio a vital partner. The company has relied on the state’s talented and committed workforce to keep its original equipment and aftermarket facilities operating smoothly and the quality of its products at the highest level.

Schaeffler strives to be a strong, contributing corporate citizen in each of the communities it operates, and looks forward to developing a positive relationship with the City of Dover and Tuscarawas County.  As part of its commitment to Ohio, Schaeffler recently completed an expansion in Wooster of almost 90,000 square feet to produce electric motors and components for electric powertrain systems.  Schaeffler also announced an increased relationship with The Ohio State University (OSU) to create a new battery cell research and development centre that will open in 2025.

Schaeffler will plan a groundbreaking event later this year to commemorate the start of construction at its future site. More information on this event will be available in the near future.

Ambitious growth plans in the Americas

Schaeffler has 15 plants in the Americas region and five Research and Development locations, with U.S. manufacturing locations in Ohio, South Carolina, Missouri, and Connecticut and has made sizeable investments in the region over the past decade. The U.S. represents a strategic growth market for the global manufacturer.

Schaeffler chose Dover, Ohio for the new manufacturing facility which will be a cornerstone to the company’s journey toward shaping a sustainable and efficient future in motion technology.

Schaeffler is reviewing if this new facility is a potential candidate for benefits provided under the U.S. Inflation Reduction Act with the goal of further improving the domestic electric vehicle supply chain and local workforce skill sets.

Klaus Rosenfeld, CEO of Schaeffler AG, concluded: “We are convinced that the trend towards more electrification will continue. At the same time Schaeffler is ideally positioned to benefit from its technological leadership in hybrid and fuel-efficient technologies, in particular in the US. On that basis we are committed to support our clients achieve their emission reduction targets and to realise our growth ambitions.”

When your business involves sending hundreds of workers out to disconnected sites where they could be exposed to dangerous gases, safety should be a top priority. But how can real-time insights and actionable data help enable you to offer your workforce enhanced protection? This was the challenge facing Cappagh Browne Utilities Limited, a company specialising in repairing and maintaining wastewater networks across the southeast of England. Learn more about their experience.

As managing director of Cappagh Browne, Jeff Birtwhistle plays a key role in helping to keep the sewers of south-east England flowing. With over 30 years’ experience in heavy civil construction, nuclear energy, and utilities, he’s always looking for innovative solutions to help the company improve the service it offers customers – and protect its workforce. So when we introduced our latest generation connected gas connector, the ALTAIR io™ 4 Connected Gas Detector, Jeff was keen for Cappagh Browne to be able to reap the benefits.

“When it comes to innovation and new technology, MSA Safety is one of our key and invaluable partners,” he says.

The gas detector that is redefining safety management

Cappagh Browne was already using a previous generation connected gas detector from MSA Safety that provided certain data for remote monitoring to help protect workers and respond to emergencies. After experiencing those benefits, he wanted to enhance them even further with real-time data. The ALTAIR io 4 Connected Gas Detector does this, helping to give Cappagh Browne the chance to leverage new MSA Safety technology, improve overall business efficiency and response times, and significantly improve safety for workers.

Offering immediate, on-site connectivity

The power of the ALTAIR io 4 Connected Gas Detector lies in its combination of built-in cutting-edge, CAT-M LTE cellular connectivity and integration with the MSA Grid. Part of MSA Safety’s Connected Work Platform, the ALTAIR io4 Connected Gas Detector can be deployed in seconds, right out of the box. What’s more, no IT is required for updates because they are delivered securely from our cloud to your fleet. When the device is in its dock, it knows when it needs a bump test or calibration to be compliant and immediately starts to run the relevant test.

And with industry-leading XCELL® sensors it can stand up to tough use in challenging conditions, resistance to extreme temperatures, the ability to withstand a 25-foot drop and a dust and waterproof IP68 rating.

Real-time insights

Matt Reid, Head of Fleet for Cappagh Browne, says they are already experiencing the benefits of upgrading to the ALTAIR io 4 Connected Gas Detector. “We have over 350 employees working across various remote sites in potentially hazardous environments. So real-time safety monitoring is important,” he explains. “Now, with the ALTAIR io 4, we’re able to use real-time data to establish who to use on a particular job because we can see what exposure they’ve had over the last week.”

“We can send one person out to a job and then, if they need help, we can send another person out with an ID tag to ‘fob on’ to the same device. We can then track both people safely within the seven-day period to make sure they don’t exceed their exposure limit.”

Keeping workers safe throughout the day

Managing Director Jeff Birtwhistle adds that it’s the ability to get immediate feedback when a worker’s exposure limit to dangerous gases has been reached that is taking the company’s safety management to new levels. “Being able to intervene on a worker’s behalf and pull them out of a job to protect them is fantastic. It means we can keep our most valuable asset –our people – safe,” he says.

Improving compliance

The real-time data and actionable insights offered by the ALTAIR io 4 Connected Gas Detector are also helping to simplify regulatory compliance for Cappagh Browne and enabling supervisors to identify behaviors that don’t meet safety standards, which can help make workers more accountable.

Since introducing the solution, the company has experienced zero safety alarms. However, as Matt Reid explains, a worker was able to use the inbuilt alarm to call for help in an unusual situation.

“We had an instance where a guy became physically locked out of his vehicle and didn’t have his phone on him. He pushed the alarm button to call for help and we were able to get a second set of keys over to him to unlock the vehicle and get him on the road again.”

The partnership with MSA Safety continues

Both Jeff and Matt know that at some point in the future they will inevitably be looking for new safety enhancements that they cannot envisage right now. But they are confident that when that time comes, MSA Safety will be there, just as it has been for real-time gas detection monitoring. For now, they are enjoying the enhanced safety that the ALTAIR io 4 Connected Gas Detector offers their workforce.

Fleet manager Matt Reid sums up the benefits. “Using ALTAIR io 4 means we can send our employees home safely to their families every night and that Cappagh Browne can see them again every morning when they turn up for another day’s work.”

Keen to see what this technology can do for safety management at your business too? Watch our case study video and find out more about how the ALTAIR io 4 Connected Gas Detector is redefining safety.

Watch the video to find out more about Cappa Browne’s experience using MSA Safety’s ALTAIR io 4 Connected Gas Detector.

Long before a racing season concludes, the Mercedes-AMG PETRONAS Formula One Team is already thinking about improvements to the following year’s car. This complex process sees the majority of car components redesigned. In production, they rely heavily on VERICUT verification, simulation and optimisation software from CGTech, a core production engineering resource at Mercedes-AMG PETRONAS Formula One Team for over two decades.

The process of new car development has evolved over time. Not so long ago, a Formula One car would undergo a complete redesign each year, with the exception of commodity parts like fasteners. With the introduction of the cost cap at the start of the 2021 season, all that changed. Non-performance components or parts already performing at the right level can be carried over to the following season. Today, Mercedes-AMG PETRONAS Formula One Team carries over a much larger quantity of machined car components each year, in comparison to pre- cost cap seasons.

Robert Brown, Machine Shop Manager at Mercedes-AMG PETRONAS Formula One Team, says: “It’s changed the nature of how we work. Now, as soon as a decision is taken to carry over a component type, we can use some of our spare ‘summer capacity’ to manufacture the carry over, meaning we can focus on redesigned performance parts when they start arriving in time for the following season.”

Cost counting

Close liaison between design engineering and production engineering has become more important since the cost cap implementation. Historically, designers would simply create the part they wanted without much consideration for machining costs.

“It’s different today: we can point out a small design change that might reduce the machining cost by two-thirds, for example,” says Mr Brown. “The voice we have in the design cycle is much louder than a few years ago.”

James Peddle, Production Engineer at, goes deeper into the process: “When we receive a redesigned performance part, we start by assessing how many operations the machining process will require to produce the component in the most efficient way possible. We then look at the fixture requirements and start programming.”

Clear the air

This stage of the process also sees the creation of a routing and an estimate of cycle time, which the team can use to approximate a cost. What follows is the beginning of the optimisation phase, where production engineers look to reduce the lead time even more. Here, the team relies on tools such as the VERICUT Air Cut Optimisation module, which can cut cycle times considerably.

“Air Cut Optimisation is a very safe optimisation to apply,” says Mr Peddle. “It doesn’t work the cutters any harder or affect part quality: it simply reduces the amount of time that cutters are not in contact with the component.”

“To ascertain the time required for the machining element of making a component, we simply use the output time calculated by VERICUT,” he adds. “The machine kinematics in VERICUT’s virtual environment are such that we’re confident the time reported will match the real run time.”

Safety first

Producing complex redesigned components economically and safely is seemingly unthinkable without the help of VERICUT.

“Primarily it would be unsafe and massively labour intensive,” states Mr Brown. “I think the days are gone when you can just read the X, Y, Z co-ordinates of the G and M codes on the screen – not with the complexity of parts today. At peak times, one operator will be responsible for multiple machines, running brand new CNC code. Ensuring the machines run safely without using VERICUT? Forget it.”

Adds Mr Peddle: “A lot of our programs have millions of lines of code. We don’t have enough people to run through that on a line-by-line basis without VERICUT. We would probably need to double our labour resources.”

A meeting of minds

Among the many beneficial features of the software is CGTech’s NX® Interface, which provides an easy and convenient way to verify NC programs directly from within NX, the CAM system in use at Mercedes-AMG PETRONAS Formula One Team.

The interface can verify individual CNC programs, a series of selected CNC programs or a complete sequence of operations. All CNC program and tooling information transfers automatically to VERICUT. Design, stock and fixture models also transfer automatically in their proper orientation. Notably, the VERICUT process runs external to NX so users can continue working in the CAM software while verifying the CNC program.

“The interface between NX and VERICUT is very impressive,” says Mr Peddle. “We know with confidence that we’re simulating exactly the same scenario as intended in our CAM session. Moreover, VERICUT simulation is quick. Even with a complex part like an axle, which has a run time of around 45 hours, it doesn’t take long to check for collisions, gouges and excess material.”

Losing weight

Every year, the redesigned parts coming through at Mercedes-AMG PETRONAS Formula One Team seem more challenging. Weight reduction, without compromising functionality, is at the heart of many modifications.

“This always creates a challenge for production engineers who must keep the component stable during machining,” explains Mr Brown. “We might need to apply special tools or cutting strategies; get really creative about how we machine certain features such as very deep face grooves. The ability to simulate those operations and replicate custom tools in VERICUT is really useful and gives us so much confidence.”

He continues: “For example, a component may have a very thin wall thickness through the bore. There’s no way of using a conventional boring bar in the Z axis of a CNC turning centre due to the profile. We therefore use modified boring bars and machine the bore at various angles. It’s complex, but by applying VERICUT we knew it would be safe. Without the software it would require a skilled operator to be present at the machine, listening for things like a change in harmonics to try to understand what is happening in the cut area inside the bore.”

License to be creative

Aside from the production engineering benefits, the use of VERICUT at Mercedes-AMG PETRONAS Formula One Team also provides designers with a notable boost.

“We get quite a few requests from design engineers asking if a new component is machineable,” explains Mr Peddle. “Sometimes it’s an easy yes or no answer. But if not, we quickly develop some tool paths for the part and run it through VERICUT. The software provides us with the answer, and maybe even one or two ideas about how to make it easier to machine. This capability allows design engineers to make positive decisions at the concept stage.”

Mr Brown adds: “VERICUT gives our designers the confidence to be creative. Without simulation we would probably be asking them to reign in their creativity, potentially compromising performance. We know from experience that VERICUT not only has a hugely beneficial impact on production, but also on design.”

Resolve Optics is a leading developer of custom optical modules – design optimised to perfectly match your application. An optical module is a system of optical components that does more than just transmit a single image. For example, in interferometry – an optical module may use beamsplitters or prisms to create many images from a single image.

Rob Watkinson, sales manager at Resolve Optics said “As a developer and supplier of custom lenses and optical systems to leading camera, sensor, and optical instrument manufacturers our aim is to help these customers keep at the forefront of the markets they serve through ongoing cooperative developments and providing continuous support.

He added “One such customer is Specialised Imaging – technological market leader in ultra-high-speed imaging and ballistic range cameras. Their SIM family of ultra-high-speed cameras are used by research laboratories around the world. These state-of-the-art cameras can capture up to thirty-two images at one billion frames per second enabling analysis of even the most fleeting of phenomena. To help the SIM camera range remain the ultra-high-speed multichannel imaging camera of choice for researchers working at the edge of what is possible and solving new applications challenges – Resolve Optics recently supplied a third generation ultra-high-speed camera optical module that is not only more user friendly but also provides improved state-of-the-art performance”.

In this latest development a key objective was to make it easier for Specialised Imaging to precisely align their sensors with the eight ports on the ultra-high-speed optical module. To provide this enhanced ease-of-use facility Resolve Optics developed a new sensor mounting system that enables easy adjustment of the whole port in x and y planes. This new adjustment system allows users of SIM ultra-high-speed imaging cameras to align their systems significantly quicker and with much more accuracy than was previously possible.

Managing Director of Specialised Imaging – Wai Chan commented “I am pleased to say that the Resolve Optics optomechanical design team has again risen to the challenge and designed a new and improved optical module that meets all of our specification needs of our SIM cameras.”

For further information on design and development of custom optical modules please visit https://www.resolveoptics.com/optical-modules/ or contact Resolve Optics on +44-1494-777100 / sales@resolveoptics.com. For further information on ultra-high speed imaging cameras from Specialised Imaging please visit www.specialised-imaging.com.

STMicroelectronics, a global semiconductor leader serving customers across the spectrum of electronics applications, announced an all-in-one, direct Time-of-Flight (dToF) 3D LiDAR (Light Detection And Ranging) module with market-leading 2.3k resolution, and revealed an early design win for the world’s smallest 500k-pixel indirect Time-of-Flight (iToF) sensor.

“ToF sensors, which can accurately measure the distance to objects in a scene, are driving exciting new capabilities in smart devices, home appliances, and industrial automation. We have already delivered two billion sensors into the market and continue to extend our unique portfolio, which covers all types from the simplest single-zone devices up to our latest high-resolution 3D indirect and direct ToF sensors,” said Alexandre Balmefrezol, General Manager, Imaging Sub-Group at STMicroelectronics. “Our vertically integrated supply chain, covering everything from pixel and metasurface lens technology and design to fabrication, with geographically diversified in-house high-volume module assembly plants, lets us deliver extremely innovative, highly integrated, and high-performing sensors.”

The VL53L9, announced today, is a new direct ToF 3D LiDAR device with a resolution of up to 2.3k zones. Integrating a dual scan flood illumination, unique in the market, the LiDAR can detect small objects and edges and captures both 2D infrared (IR) images and 3D depth map information. It comes as a ready-to-use low power module with its on-chip dToF processing, requiring no extra external components or calibration. Additionally, the device delivers state-of-the-art ranging performance from 5cm to 10 meters.

VL53L9’s suite of features elevates camera-assist performance, supporting macro up to telephoto photography. It enables features such as laser autofocus, bokeh, and cinematic effects for still and video at 60fps (frame per second). Virtual reality (VR) systems can leverage accurate depth and 2D images to enhance spatial mapping for more immersive gaming and other VR experiences like virtual visits or 3D avatars. In addition, the sensor’s ability to detect the edges of small objects at short and ultra-long ranges makes it suitable for applications such as virtual reality or SLAM (simultaneous localization and mapping).

ST is also announcing news of its VD55H1 ToF sensor, including the start of volume production and an early design win with Lanxin Technology, a China-based company focusing on mobile-robot deep-vision systems. MRDVS, a subsidiary company, has chosen the VD55H1 to add high-accuracy depth-sensing to its 3D cameras. The high-performance, ultra-compact cameras with ST’s sensor inside combine the power of 3D vision and edge AI, delivering intelligent obstacle avoidance and high-precision docking in mobile robots.

In addition to machine vision, the VD55H1 is ideal for 3D webcams and PC applications, 3D reconstruction for VR headsets, people counting and activity detection in smart homes and buildings. It packs 672 x 804 sensing pixels in a tiny chip size and can accurately map a three-dimensional surface by measuring distance to over half a million points. ST’s stacked-wafer manufacturing process with backside illumination enables unparalleled resolution with smaller die size and lower power consumption than alternative iToF sensors in the market. These characteristics give the sensors their excellent credentials in 3D content creation for webcams and VR applications including virtual avatars, hand modeling and gaming.

First samples of the VL53L9 are already available for lead customers and mass production is scheduled for early 2025. The VD55H1 is in full production now.

Pricing information and sample requests are available at local ST sales offices.

ST will showcase a range of ToF sensors including the VL53L9 and explain more about its technologies at Mobile World Congress 2024, in Barcelona, February 26-29, at booth 7A61.