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By Prashanth Mysore, Strategic Business Development and Industry Marketing Director at DELMIA, part of the Dassault Systèmes Group. Providing insight into Digital twin technology, DELMIA have played a vital role in the importance of digital twin technology within manufactures around the globe.

Digital Twin technology has quickly become a staple with many of the largest manufacturers in the automotive and industrial engineering sector around the world thanks to its ability to provide huge amounts of value in saving time and optimising plant effectiveness. Whilst uptake in smaller manufacturing firms has been slower, those within the sector are slowly starting to see the value that digital twin technology can bring, no matter the size of the business.

What is Digital Twin & Virtual Twin technology? 

Digital twin technology allows manufacturers to gain a digital representation of a real-world system – the digital twin mirrors the software or model to gain data and insight that can update

Digital twin is actually an executable model of a physical system. The physical system can be a factory or a plant or a mine or resource any of them. Which brings in learning and experiences from the physical part, so that you can continuously update your distribution model. The next step up from digital twin is virtual twins, which provide a far more dynamic look factory systems. Virtual twins provide businesses with the ability to visualize models and simulate sophisticated experiences—whereas digital twin solutions are static. Virtual twin essentially shows manufacturers exactly what can be executed and implemented in the real world, it’s primary focus is to give actionable solutions to improve efficiencies. 

In fact, Virtual Twin technology helps us visualise a model not only of the product, but manufacturing and operations as well. When thinking about the capabilities of digital twins, they operate in a closed loop of “ability to ability”, but virtual twin goes beyond that. It provides the opportunity where you can control the real world with the virtual world with this closed loop ability and we can bring innovation to expand on that. Virtual Twin solutions can be beneficial for almost any manufacturing organisation, both small and large. It also empowers workforce of the future, and considering current conditions, it’s like bringing in new resiliency while people are working in the new or next normal due to this pandemic.

Which Industries Can Benefit from Digital & Virtual Twin?

Digital twins initially found their way into a select few industries where businesses could easily see value and return on investment. The automotive & industrial equipment sectors were the two main areas that invested in digital twin technology initially, along with oil and gas shortly after. These industries had a clear need for the insights provided by digital twins to streamline processes and provide extra efficiency.

In more recent times, manufacturing and life sciences are beginning to really catch up on the benefits that are brought about by digital twins as they’re really relying on the twins ability to provide sophisticated models that can be acted upon. In manufacturing and the operations industries, the overall goal for most businesses is to achieve greater profitability in a safe and sustainable way.

The length and breadth of industries that can adopt this type of technology stretches far and wide, and the same can be said about virtual twin technology, as this is essentially a step further than the insights offer by digital twins.

Why Are Digital/Virtual Twins So Important for Manufacturers?

There are many benefits to having digital or virtual twins integrated into your workflow as a manufacturing business, though the most pertinent are normally time, cost and resource savings, increased levels of safety for all employees.

In recent years, there’s been an increased focused on sustainable manufacturing and a ‘circular economy’, with real emphasis being placed on improving the overall productivity and safety of processes. Alongside this, there’s been a real shift in manufacturing bosses looking for more control over production, whilst also minimising costs. All of this is covered by digital/virtual twins, as they give manufacturers access to important information about cutting costs whilst maintaining, and improving, workflows. 

Whilst manufacturing and operations industries are becoming ever more complex due to the digitalisation and innovation within each sector, so it’s important that things are made as simple as possible. Operation lead times can begin to become longer and longer if inefficiencies in the new workflow aren’t ironed out, and that’s where digital and virtual twin technology comes in to play. Having the insight and agility to make changes in manufacturing is exceptionally important, especially with the supply chain issues that are currently facing the vast majority of manufacturers around the world.

To really emphasise the effectiveness of virtual twin technology in particular, in one case study, DELMIA saw plant effectiveness increase by 250% after the installation of a virtual twin. The twin provided an in-depth analysis of inefficiencies and provided the manufacturer with simulation models that would help to combat those inefficiencies. Alongside this, employee safety and fulfilment rose by 5% in time savings.

In a separate case study, DELMIA saw another company increase on time deliveries by 50% thanks to better planning techniques and technologies. There was also a 50% reduction in lead times, which enabled the company to maintain high levels of orders, whilst shipping a higher percentage out on time to consumers. This is obviously exceptionally important when you consider how consumers are changing their behaviour when it comes to reduced lead and delivery times.

In summary, digital and virtual twins are quickly becoming the staple within many industries thanks to the number of benefits they bring to each company. Manufacturing and logistics in particular can benefit from the technologies, thanks to vastly reduced lead times and help when it comes to planning efficiently.

Manufacturing sheet metal parts is challenging: the cost of each component is lower than other industries like metal machining, which drives down the resources available to invest in quality control. Nevertheless, inspection remains critical for every sheet metal application. Here Matt Parry, applications engineer at industrial metrology specialist The Sempre Group, and Olivia McNeill, Sales & Marketing Manager at InspecVision, explain why automating inspection is critical.

If inspection systems are expensive to purchase and operate, some manufacturers may instead tolerate production errors. However, this approach increases the risk of customer complaints, which will only lead to suppliers scrambling to make replacement parts.

Make UK recently estimated that increasing energy bills threaten 60 per cent of manufacturers, compared with eight per cent just four months earlier. The increase in energy prices has boosted metal costs and the expense of running production machines.
For both these reasons a smarter, more effective quality process is needed.

Out with the old

Although coordinate measuring machines (CMMs) and laser scanners are regularly found in quality assurance (QA), they are poorly suited to sheet metal inspection. So much so sheet metal manufacturers often end up leaving them unmanned and going back to using callipers — a relatively basic measurement instrument.

CMMs are more expensive to run than more up-to-date systems as they require sophisticated skills to operate. They are also difficult to use accurately on sheet metal parts. For example, metal sheets often have a kerf or edge profile.  If a CMM touches the edge at the top or bottom, the location can vary by as much as 0.1 mm, even on thin parts.

Sheet metal parts are largely defined by their edges and laser scanners are very poor at picking up these thin and shiny edges. Generating meaningful data means scanning at a right angle to the surface, in this case the edge. This can make setting up or using a laser scanner a slow and skilled process, which could generate suboptimal measurements anyway.

Introducing automation

With skills shortages and the increasing price of metal impacting sheet metal facilities, automation can alleviate pressure and smarten processes. Over the last 30 years or so, automated assembly machines, conveyor systems and other technologies have transformed manufacturing processes. However, even now, parts are often checked with manual tools like callipers, which have remained relatively unchanged in 300 years.

While the automation of production machines has helped, if there is an issue with setup or input and no accurate check on the output, manufacturers risk creating an open loop system. The more automated the production, the more important it is to close this loop and inspect the output smartly, accurately, and reliably.

Closing the loop

Manufacturers can address this imbalance by investing in a fast inspection system that they can automate in both setup and inspection. Bringing these systems onto the factory floor, next to production machines, reduces the time taken to load the sheet metal part onto the inspection system while bringing manufacturing and quality processes together.

InspecVision Planar is a fully automated 2D field of view (FOV) scanner capable of measuring multiple parts with multiple dimensional characteristics. It’s easy to operate — manufacturers simply place the sheet metal part on a glass table, which is back lit with a diffuse light and the silhouette is imaged above with a camera. The measurements are taken in the time it takes to capture the image, usually around 0.01 seconds.

Generally, 3D scanning is more complex, with several rotations and scans required to generate a full picture of a part and its geometries. While 3D inspection takes around five minutes, compared with five seconds for a 2D scan, both systems allow manufactures to import dimensions and tolerances from their CAD files to automatically create a report.

Although rising energy costs and skill shortages are a concern for manufacturers and sheet metal facilities, automation can help by saving time and improving accuracy.  Using smart technologies to optimise production is one thing, but adding automated scanners for inspection purposes is essential as more companies embrace Industry 4.0.

For more information about 2D scanning and sheet metal inspection, visit https://www.thesempregroup.com/2d-scanning/inspecvision-planar/.

RS Group has announced the launch of the next phase of DesignSpark, RS’ fast-growing online community for engineers. It offers a suite of design tools including DesignSpark Mechanical and DesignSpark PCB, plus comprehensive 2D/3D and electronics part libraries, and a host of design resources such as technology articles, projects and community forums.

Unveiled today, this next phase in the DesignSpark engineering community has been designed to present an enhanced and increasingly personalised experience for members. The new DesignSpark will offer three subscription levels, respectively called: ‘DesignSpark Explorer’, ‘DesignSpark Creator’ and ‘DesignSpark Engineer’, which will enable members to select their own level of access according to their requirements for design tools and resources.

DesignSpark Explorer

Likely to suit students, makers, and designers, DesignSpark Explorer will enable members to retain the same community access and award-winning tools and design resources that they enjoy today – completely free – enabling them to quickly make the leap from concept to prototype.

Key tools available in DesignSpark Explorer include: DesignSpark PCB, the award-winning rapid-prototyping tool for circuit design that allows the creation of schematics, transfer to a PCB layout and preparation for production, all backed by pre-built component libraries and tools to ensure error-free PCBs; and DesignSpark Mechanical, a direct modeller that requires no prior experience with 3D CAD software and enables users to freely create and modify geometry. Excellent for prototyping and conveying requirements to the engineering team, DesignSpark Mechanical enables the rapid prototyping or reverse engineering of any physical object.

In addition to engineering support and public forums within the DesignSpark engineering community, DesignSpark Explorer subscribers will continue to have access to more than 100 million 3D models and 2D symbols for circuit design, and the ability to perform searches on one billion parts, accessing data sheets and part lifecycle status information.

DesignSpark Creator

For users looking for even more advanced tools and resources, further DesignSpark options are now available featuring design tools with enhanced features. For example, and ideal for serious makers, pro-makers and SMEs, DesignSpark Creator, at a price of £9.99 per month, will offer the same tools and resources available in Explorer, but will also provide an enhanced version of DesignSpark Mechanical. This will include a 3D Mirror tool and detailing tools to annotate parts and create manufacturing drawings, and enhanced part libraries that provide further intelligence on component capabilities and status. In addition, there will be skills and learning videos, tutorials and tips contributed by experts from the DesignSpark community.

DesignSpark Engineer

Additionally, DesignSpark Engineer, at a price of £14.99 per month, brings the ultimate in design creativity and flexibility for the most demanding users, making it ideal for professional-level design engineers. DesignSpark Engineer offers the same enhanced features of DesignSpark Mechanical available in DesignSpark Creator and expands significantly on DesignSpark PCB with a new advanced feature set, including the use of blind and buried vias for high-density PCB design, custom pad shapes, differential pair routing for high-speed signals, a panels editor, and hierarchical schematic block capability. As well as the high support levels available in Creator, DesignSpark Engineer also provides even more parts intelligence data, including export compliance data and PCN/EOL notifications, plus aid with component alternatives.

The full suite of capabilities available to paying subscribers would be typically worth an estimated £1000. Through the subscription model, RS is now able to offer these at an entry price level equivalent to a Netflix subscription per month.

Free Trial Period

In addition, as part of the launch, RS is introducing a free trial period to allow all DesignSpark members to try out the ‘Creator’ and ‘Engineer’ subscription options with their more advanced and fully featured versions of the DesignSpark tools, enabling them to assess these additional capabilities before deciding which option will best suit their needs. The free trial period begins today – 24 January 2023 – and will run until 31 March 2023.

“Today’s launch is the next phase in the lifecycle for our award-winning suite of design tools and design engineering resources”, said Mike Bray, Vice-President of Innovation and DesignSpark at RS. “RS is continually aiming to enhance and personalise the design experience for engineers and through engagement with the DesignSpark community and extensive research into the needs of its members, we have recognised that one size does not fit all. Therefore, we are looking to bring the right level of resources suitable for the DesignSpark community from students and hobbyists to super makers to professional design engineers in companies of all sizes and industries. And, importantly, we are offering a solution that puts DesignSpark members in control of what and when they use a higher level of capability.”

DesignSpark Explorer, Creator and Engineer – and access to the free trial – are available at rs-online.com/designspark/home, enabling members to discover for themselves which subscription can best meet their needs. The DesignSpark tools are supported by the DesignSpark software team and by the online DesignSpark engineering community, which now has 1.3 million members.

Napier Partnership Limited, a leading international B2B technology marketing and PR agency, has been announced as the Charity Sponsor for the 2023 Instrumentation Excellence Awards.

Napier’s award-winning approach to marketing and PR helps some of the most innovative and fastest growing B2B and technology companies in the world achieve their business goals sooner. Find out more about Napier’s unique four-step approach here: https://www.napierb2b.com/approach/ 

The 2023 Instrumentation Excellence Awards ceremony will take place on 19th October 2023 at the Grand Connaught Rooms and will once again take place alongside the Electronics Industry Awards making it the night of the year for networking. The 2022 ceremony was a huge success and has cemented it as a must attend event; an Instrumentation Excellence Awards trophy now represents a truly unique stamp of approval, opening up doors for new business opportunities.

Nominations for the 2023 Instrumentation Excellence Awards are now open via the online portal: www.instrumentationawards.co.uk.

To find out more about sponsorship opportunities for the event, please contact Louise Tiller by emailing ltiller@datateam.co.uk. To make your nomination for the 2023 awards or to find out more about the event, please visit: www.instrumentationawards.co.uk.

There is less than one week left for UK-based engineering innovators to submit entries for this year’s MacRobert Award – the longest running and most prestigious award for UK engineering innovation.

Entries close on Monday 31 January at 5pm – companies who choose to enter will be competing for one of the Royal Academy of Engineering’s most distinguished prizes, with a gold medal and a tax-free £50,000 prize at stake for the winner.

Previous winners have helped to transform the world we live in, delivering outstanding innovation, commercial success and tangible social benefit. Since 1969, the MacRobert Award has established an enviable track record of spotting step-change innovations that have gone on to be highly successful as well as beneficial to society. 

Many of the UK’s best-known companies have won the award during its 50+ year history, from Rolls-Royce and Jaguar Land Rover, to mini-computer pioneers Raspberry Pi and structural engineering experts Arup and Buro Happold. The 2022 winner was Quanta Dialysis Technologies for its innovative approach to a portable dialysis machine, inspired by the design of a fast-food drinks dispenser.

Chair of the judging panel Professor Sir Richard Friend FREng FRS explains what he looks for in entries: “The MacRobert Award is for innovation in engineering and we really want to see that innovation. Something that you didn’t expect to see but when you do it makes you think ‘my goodness that is clever’. There is no particular formula for a winning product. But when you see it, you know it. 

“The innovation needs to be commercially successful, and if you look at the previous winners of this award, they include everything from emerging companies right up to large multinational businesses. 

“Common to all winners is the quality of the team. The award is for a team and they need to work together in a special way. The diversity of groups is the magic. You need disparate skills and diversity of thought to understand how to manufacture, how to find who the customers really are and what they want to buy.” 

To enter the award visit: https://macrobertaward.raeng.org.uk/about-the-award/how-to-apply 

The Tomorrow’s Engineers Code has reached an important milestone – there are now over 250 members who have pledged to increase the diversity and number of young people entering engineering and technology careers.

Managed and delivered by EngineeringUK for the engineering community, The Tomorrow’s Engineers Code brings together organisations working towards common goals. Signatories of The Code make 4 pledges – to inspire connection, drive inclusion, showcase engineering and improve the impact of their engineering outreach.

The 250^th organisation to join The Code is the Society of Operations Engineers (SOE), a Professional Engineering Institution (PEI) and registered charity with around 16,000 members working to inspect, maintain and manage the equipment and machinery which keeps people and businesses safe. SOE actively champions the next generation of engineers, which aligns with The Code’s mission.

SOE joins other engineering firms and professional institutions, as well as government departments, charities and STEM delivery providers, in becoming members of The Code community. Other Signatories include the Institution of Engineering and Technology, NatWest, STEM Learning, Siemens, and the Department for Education.

Melanie Washington, Director of Engagement Projects at EngineeringUK, said: “We’re proud that, in just over 2 years, The Tomorrow’s Engineers Code community has grown to over 250 members. Given the acute skills shortage and the UK’s net zero ambitions, it’s crucial that we continue to attract more young people, from all backgrounds, to go into engineering and tech careers.

“With The Code and its 4 pledges, we’re able to make important strides towards this by improving the quality, inclusivity, targeting and reach of activities designed to inspire young people. I’m delighted that we’ve welcomed so many new members and, I‘m confident that, together, we can inspire more and more diverse young people so they choose a career in engineering and technology.”

Education provider Marvelous Manufacturing is another recent Signatory, joining a community sharing expertise and working together. By signing The Code, Marvelous Manufacturing commits to the 4 pledges. Angela Lawlor, Managing Director at Marvelous Manufacturing, said: “[We] are a huge advocate for collaboration and believe that by working with other businesses we can make a much bigger impact.”

Hugh Baird College, a further education institution located in Merseyside, also recently joined The Code, signing up to its 4 pledges. Dr Charuni Dissanayaka, Lecturer Building Services – STEM Technical Level Lead at Hugh Baird College, said the college “joined The Code to better understand the ways to drive up the quality of engagement activities we undertake with our leaners.”

The Institution of Royal Engineers recently joined as a Supporter of The Code, committing to play an active part in the community. Robert Drew, Digital Services Manager at the Institution, said: “As a Professional Engineering Institution we strive to support and develop our current and next generation of military engineers, The Code supports that mission.”

Any organisation with UK operations that funds, designs and/or delivers engineering outreach activities, or intends to, is invited to become a Signatory, which is free to do. Any organisation not meeting these criteria, but supporting the aims of The Code, can join as a Supporter.

To find out more and to join The Code, visit: www.code.tomorrowsengineers.org.uk

Scientists, led by University of Bristol, have been studying a fish sensory organ to understand cues for collective behaviour which could be employed on underwater robots.

This work was centred around the lateral line sensing organ in African cichlid fish, but found in almost all fish species, that enables them to sense and interpret water pressures around them with enough acuity to detect external influences such as neighbouring fish, changes in water flow, predators and obstacles.

The lateral line system as a whole is distributed over the head, trunk and tail of the fish. It is comprised of mechanoreceptors (neuromasts) that are either within subdermal channels or on the surface of the skin.

Lead author Elliott Scott of the University of Bristol’s Department of Engineering Mathematics  explained: “We were attempting to find out if the different areas of the lateral line – the lateral line on the head versus the lateral line on the body, or the different types of lateral line sensory units such as those on the skin, versus those under it, play different roles in how the fish is able to sense its environment through environmental pressure readings.

“We did this in a novel way, by using hybrid fish, that allowed for the natural generation of variation.”

They discovered the lateral line system around the head has the most important influence on how well fish are able to swim in a shoal, Meanwhile, the presence of more lateral line sensory units, neuromasts, that are found under the skin result in fish swimming closer together, while a greater presence of neuromasts on the skin tend to result in fish swimming further apart.

In simulation, the researchers were able to show how the mechanisms behind the lateral line work are applicable at not just the tiny scales found in actual fish, but at larger scales too. This could inspire a novel type of easily-manufactured pressure sensor for underwater robotics, particularly swarm robotics, where cost is a large factor.

Elliott said: “These findings provide a better understanding of how the lateral line informs shoaling behaviour in fish, while also contributing a novel design of inexpensive pressure sensor that could be useful on underwater robots that have to navigate in dark or murky environments.”

The team now plan to develop the sensor further and integrate it into a robotic platform to help a robot navigate underwater and demonstrate its effectiveness.

The research for this paper was funded by Engineering and Physical Sciences Research Council (EPSRC), Biotechnology and Biological Sciences Research Council (BBSRC) and the Human Frontier Science Program (HFSP).

Laser Components will demonstrate its full range of optical and optoelectronic components at the SPIE Photonics West show in San Francisco, CA. From January 31st to February 2nd, visitors to booth 941 will be able to meet with expert engineers and discuss standard and custom product specifications. As true to its motto »beyond borders«, the company will highlight its capabilities with creative, customised product developments that provide the greatest freedom to meet complex challenges.

Components for 3D LiDAR

The Laser Components group is among few manufacturers in the market, that produce both emitters and detectors for LiDAR and other Time-of-Flight applications. Pulsed Laser Diodes (PLDs) from Canada and Silicon Avalanche Photodiodes from its facility in Chandler, AZ are at the forefront in the race for shorter pulse lasers, higher performance, and more sensitive detectors. Continuing investment in multi-junction technology with trenched chip design led to the high-efficiency PLDs on display at SPIE Photonics West. 

Complex, Reliable Laser Optics 

The laser optics business unit in Germany further expanded production capacities and measurement capabilities to provide more flexibility and shorter delivery times for small quantities and series production. Using PVD, IAD and IBS coating technologies, experts are able to realise complex optics such as thin-film polarisers with special functions or polychromatic beam splitters that can simultaneously direct three or more wavelengths. A newly installed cavity ring-down measuring station is able to measure reflectivity values well above 99.95% and offer customers proof that these specifications have been met.

3D Radial Measurement

FLEXPOINT Radial, the latest addition to an ever-growing range of laser modules, was specifically developed for a laser triangulation system that provides a detailed look inside pipes and pipelines. The laser module generates a 360° line with a consistently high homogeneity without any moving parts. Scanners equipped with this robust module can detect irregularities down to 50µm.

Select Suppliers

In addition to these proprietary products, the portfolio displayed at the Laser Components booth also includes products from international high-end suppliers that breathe the same spirit of innovation and customisation with Spatial Light Modulators from HOLOEYE, CODIXX’ colorPol polarisers, and laser pulse drivers from PicoLas as well as UV LEDs from Bolb and Photon Wave or Micro-Hybrid’s IR emitters.

Visit Laser Components at SPIE.Photonics West

January 30 – February 02, 2023; Booth 941

 For further information SPIE Photonics West (lasercomponents.com)

Analog Devices has announced that its Chief Executive Officer and Chair of the Board of Directors, Vincent Roche, has become a member of the World Economic Forum’s Alliance of CEO Climate Leaders. Analog Devices is the first semiconductor company to join the Alliance, a global community of more than 120 CEOs and Senior Executives from large multinational organisations committed to accelerating the pace of climate change action across their value chains.

“Analog Devices’ core purpose is to work with our customers to create the technological breakthroughs that enrich lives and the world around us,” said Mr. Roche. “From electrification to energy management to industrial efficiency, a focus on combating climate change is woven throughout our business and operations. Joining the Alliance is a natural reflection of our ambition and actions to advance sustainable solutions globally to enable and accelerate the net zero transition. We look forward to working with and alongside Alliance members across our industries.”

Founded in 2014 as a World Economic Forum initiative, the Alliance and its members seek to involve policy makers in their shared commitment to reducing emissions by more than 1 gigaton annually by 2030 and reaching net zero by 2050. The Alliance publishes white papers and reports to guide leaders on carbon removal, as well as facilitates cross-industry collaboration and knowledge sharing.

“We are delighted to have Vince join us as a member of the Alliance of CEO Climate Leaders,” said Pim Valdre, World Economic Forum’s Head of Climate Ambition Initiatives. “Analog Devices’ commitment to achieve net zero by 2050 or sooner is just one example of its ESG excellence that can inspire others in the semiconductor industry to follow. We look forward to adding the experience and vision offered by Vince and the Analog Devices team.”

Endress+Hauser Mexico has invested roughly 10 million euros in a new building. The recently occupied sales and service centre is located in Naucalpan in the Mexico City metropolitan area. With 4,100 square meters of usable space, the centre includes modern office facilities, an extensively equipped customer experience and process training centre and a complete calibration lab.

Strengthening customer relationships 

The new building in Naucalpan reflects the solid growth of the Sales Centre in recent years. It demonstrates a connection with the market and customers and enables further growth. At the heart of the building is a process training centre where customers can practice using a variety of measurement instruments and simulate conditions similar to their own operating environments. Working together with experts from Endress+Hauser, they can then develop new solutions for their applications.

Attractive work setting

The building features numerous spaces and facilities designed with the needs of the employees in mind, allowing them to flourish and feel at home in their new work environment. The amenities include a gym, a nursing room for mothers, and a library, plus various places for individual and collective work in open spaces to ensure that the day-to-day work activities can be carried out in a productive and attractive setting.

Focus on sustainability

Endress+Hauser places a value on sustainability and energy efficiency with all of its construction projects. The new building in Mexico thus features solar panels. In addition, a water treatment and cleaning system was developed that feeds 7.2 cubic meters of water into the climate control and plumbing systems on a daily basis. Because of these measures, the new building was certified gold under the LEED system (Leadership in Energy and Environment), proving that it achieves significant energy and resource savings over its lifetime.