Aerospace manufacturing trends emphasise precision and multifunctionality. Machine tools evolve to meet strict requirements, handling advanced materials and enhancing efficiency while maintaining safety standards.

What are the emerging trends in machine tools for aerospace manufacturing processes?
In the dynamic landscape of aerospace manufacturing, several emerging trends are revolutionising the capabilities and roles of machine tools. One prominent development is the unyielding drive for exceptional precision. Aerospace manufacturers are increasingly imposing stringent requirements on machine tools to achieve levels of precision that align with the industry’s rigorous quality and safety standards. Aircraft components must adhere to remarkably stringent tolerances, prompting machine tools to evolve to deliver essential accuracy.

Another significant trend is multifunctionality. Aerospace manufacturers are adopting machine tools capable of executing various tasks, such as milling, turning, and drilling, all within a single setup. This versatile approach reduces the duration of operational cycles and elevates overall efficiency in the production process. By minimising the necessity for frequent machine changes and setups, manufacturers can streamline their operations and decrease the likelihood of errors.

With aerospace materials continuously progressing towards lightweight composites and advanced alloys, machine tools are adjusting to handle these materials effectively. Lightweight materials hold immense importance for augmenting fuel efficiency and curbing emissions within the aerospace sector. Consequently, machine tools must be equipped with specialised tooling and cutting methods to engage with these materials while maintaining precision and quality.

How do machine tools designed for aerospace applications differ from those used in other industries?
Machine tools designed for aerospace applications exhibit distinct characteristics to fulfil the industry’s specialised requirements. Aerospace parts demand heightened precision, characterised by highly narrow tolerances and rigorous benchmarks. This precision is of utmost importance to guarantee aircraft safety and performance. Machine tools give primary importance to sturdiness and steadfastness within the aerospace sector. They are crafted to be more resilient, effectively managing tough and demanding materials while upholding accuracy even during high-speed machining tasks.

Furthermore, due to the dimensions of aeroplane components, aerospace machine tools frequently showcase spacious work areas, enabling the production of sizable parts without compromising precision. Adherence to industry-specific quality and safety standards stands as an uncompromising prerequisite for aerospace machine tools. These devices must fulfil stringent criteria to ensure the dependability and safety of aerospace parts, which frequently hold critical roles in aircraft operations.

What are the main challenges in machining aerospace materials, and how are specialised machine tools designed to overcome these challenges?
Machining materials used in aerospace applications present distinct challenges that demand specialised solutions. Firstly, the hardness of substances like titanium and advanced composites can significantly impact the durability of cutting tools. These tough materials lead to accelerated wear of cutting tools and reduced lifespan.

Secondly, the high-speed machining of aerospace materials generates considerable heat, which can jeopardise the soundness of the workpiece. Efficient heat management prevents material distortion or alterations in its microstructure. Approaches like optimising coolant usage and implementing advanced cooling systems are employed to uphold stable temperatures throughout the machining process.

Thirdly, controlling vibrations is a crucial concern, as excessive vibrations can detrimentally affect machining accuracy. Customised machine designs integrate damping methods and heightened structural robustness to curtail vibrations and guarantee consistent cutting forces.

Lastly, attaining the necessary surface finish on aerospace components can be particularly demanding due to the distinctive attributes of these materials. The hardness and abrasive nature of specific aerospace materials can complicate the attainment of precise surface finishes. Advanced strategies for toolpaths and the use of tools resistant to abrasion are frequently employed to surmount these hurdles, ensuring that the end products adhere to the exacting quality standards mandated by the aerospace sector. Overall, effectively addressing these challenges is imperative to preserve the calibre and performance of aerospace components during the machining process.

Please discuss the indigenous production of complex aerospace components, such as turbine blades or aircraft fuselages.
The Indigenous production of complex aerospace components such as turbine blades or fuselages necessitates a blend of dedicated machine tools, a proficient workforce, and stringent quality control protocols. Numerous aerospace manufacturers collaborate closely with engineering and research establishments to formulate and enhance their production methodologies. Indigenous manufacturing bolsters self-sufficiency and reduces dependency on foreign suppliers.

What role do CNC machine tools play in manufacturing, and what are their advantages?
In aerospace manufacturing, CNC machines are indispensable, presenting various benefits that contribute to the industry’s effectiveness and quality benchmarks. Among the primary advantages is their capability for elevated precision. CNC machines deliver remarkable precision and consistency, a pivotal necessity in aerospace, where strict tolerances are essential to guarantee the security and effectiveness of aircraft parts.

Flexibility is another key advantage of CNC machine tools. They can be reprogrammed to craft diverse components, showcasing remarkable adaptability to evolving production demands. This adaptability diminishes setup durations, streamlining the shift between distinct parts or production batches.

Furthermore, CNC machines supply valuable data for overseeing processes and quality control. Manufacturers can monitor the machining process through sensors and data recording capabilities in real-time. This data can be evaluated to identify anomalies, optimise machining variables, and ensure that each part meets the aerospace sector’s rigorous quality criteria.

CNC machine tools are the cornerstone of aerospace manufacturing, presenting outstanding precision, automation, adaptability, and data-driven insights. Their integral role in forming crucial aircraft elements underscores their significance in upholding the industry’s elevated safety, performance, and efficiency standards.

How do automation and robotics integrate with machine tools in aerospace manufacturing, and what benefits does it offer?
Automation and robotics have become essential components of aerospace manufacturing, offering a range of invaluable advantages. Firstly, they enhance efficiency by reducing cycle times and elevating production rates. Mainly, robots execute repetitive tasks with exceptional precision and uniformity, minimising errors and elevating the general quality of aerospace parts. Safety is another pivotal benefit since automation can take on hazardous tasks, shielding workers from potential dangers. Integration with CNC machines allows for uninterrupted operation, facilitating lights-out manufacturing, optimising efficiency and lessening periods of inactivity. Moreover, automation substantially contributes to ensuring quality by guaranteeing consistent processes, ultimately yielding higher-quality aerospace products that satisfy stringent industry benchmarks. Overall, automation and robotics have transformed aerospace manufacturing, amplifying efficiency, safety, and the overall quality of aerospace components.

igus is adding a ready-to-install low-cost variant made from regranulated high-performance plastics to its iglidur PRT series.

It is affordable, compact, lightweight and ready to install with a mouse click: igus has added a minimalist low-cost variant to its iglidur PRT series of slewing ring bearings portfolio. The PRT-05-15-PC not only reduces costs but also protects the environment. The new slewing ring bearing consists of 97% regranulated high-performance plastics.

From the packaging machine to the assembly line to the operating table, slewing ring bearings are used in many rotary movements around a fixed axis. However, the bearings are often oversized and too expensive for many bearing points with low loads, such as those found in furniture construction or display technology. Therefore, such applications often contain metal ball bearings. The problem is that the rolling bearings often take up much space and require assembly work because they often need fitting. They are also maintenance-intensive as they require continuous lubrication to function. “To eliminate these disadvantages, we decided to add a ready-to-install, low-cost variant to our slewing ring bearing portfolio,” says Marc Trenkler, iglidur PRT Product Manager at igus. “So far, there have been hardly any ready-to-install, relatively inexpensive slewing ring bearings on the market,” says Trenkler.

Minimalist design reduces required installation space, weight and costs
The new low-cost slewing ring-bearing design follows minimalist principles. “Our goal was to produce a light, compact, ready-to-install bearing with as few components as possible,” says Trenkler. The PRT-05-15-PC consists of inner and outer rings that slide over each other without balls. It is manufactured in a cost-effective injection-moulding process entirely from lightweight, high-performance plastic – without an ounce of metal. Its diameter is 100 millimetres, only 10 millimetres high and weighs 72 grams. The reduced complexity makes the new low-cost slewing ring bearing compact, lightweight and quick to assemble. “Our employees only have to put the inner and outer ring together with a clip bearing. This allows us to offer the bearing to our customers at low cost,” says Trenkler.

Low-cost slewing ring bearing made of 97% regranulate
The PRT-05-15-PC not only reduces costs but also protects the environment. The new low-cost slewing ring bearing has a 97% content of regranulated iglidur M260 and iglidur P4 high-performance plastics. These materials, such as production sprue, have already been processed. Valuable plastics are thus saved from incineration and transferred to a sustainable circular economy. The plastic also has microscopic integrated solid lubricants that are released during operation and allow low-friction dry operation without lubricating grease for an additional environmentally friendly effect, which is a great advantage. Every year, millions of tons of lubricants pollute the environment. Finally, the new PRT is durable, especially outdoors. The polymer bearings do not rust and are resistant to contamination from grease and dirt. This means that they can be replaced less often. “The iglidur PRT-05-15-PC thus contributes to the EU sustainability strategy,” says Trenkler. That strategy is aimed at making Europe the first climate-neutral continent by 2050 while boosting economic growth.

www.igus.eu

Stäubli, a leading global industrial and mechatronic solution provider opened a $15 million facility in Bengaluru. The 25,000 sq. ft office strengthens Stäubli’s presence in the region, emphasising its commitment to nurturing growth and innovation in India. The company conducted the ‘Stäubli Partnership Forum India’ event to showcase its innovative solution capabilities and the new facility to partners. With over 100 employees, the expansion demonstrates Stäubli’s efforts towards local job creation and economic development.

The new facility located in Yelahanka, Bengaluru, represents three Divisions – Electrical Connectors, Fluid Connectors and Robotics – and houses a product showcase/ demonstration area, training rooms for customers and employees, a warehouse, and a service center. Bringing together functions such as engineering, sales, and customer services, it streamlines operations for better efficiency.

Gurupad Bhat, Managing Director, Stäubli Tec Systems India, said “This facility will help us collaborate closely with stakeholders to fast-track our localisation efforts and strengthen local engineering capabilities to increase the Stäubli footprint in India. We are dedicated to creating solutions that fit India’s unique demands. India is poised to be the next growth engine for the Stäubli Group and with this expansion, Stäubli aims for double-digit growth in its Indian operations.”

Gerald Vogt, Stäubli’s Global Chief Executive Officer, stated, “At Stäubli, we have been dedicated to delivering premium quality products and services for over 130 years. Our reliability and technical excellence are a result of our employee’s consistent focus on innovation and our industrial customers. Committed to forging lasting bonds, we cherish our relationships with customers, colleagues, and partners. We recognise the boundless potential that India offers to our business. Strengthening our local engineering and manufacturing capabilities underscores our commitment to India’s growth and our valued partners. As we look forward, we are excited to continue creating opportunities for success and progress.”

With a focus on industries such as Railway, Automotive, Pharma and Power, Stäubli has four dedicated divisions: Electrical Connectors, Fluid Connectors, Robotics and Textile, serving customers who aim to increase their productivity in multiple industrial sectors.

Recent trends in welding technology are reshaping the aerospace industry, enhancing efficiency, quality, and safety. According to Dr. T.J. Prasadrao, Executive Director (Technical), D & H Sécheron, automation, advanced techniques, and materials innovation drive change, while collaborative robots revolutionise welding processes. 

How are the latest welding processes trends in welding technology impacting the aerospace industry?
Several significant trends are influencing the aerospace industry in welding technology. One of the key impacts is heightened efficiency as emerging technologies within aviation welding expedite production processes, resulting in increased efficiency in production. Moreover, implementing advanced welding techniques promises to enhance the quality of welds. This improved weld quality is particularly crucial given the importance of safety in the aerospace sector.

An additional impact centre around is cost reduction. As these novel welding technologies become more prevalent, the potential for reducing manufacturing costs emerges, contributing to economic benefits for the aerospace industry. An equally substantial influence arises from innovation in materials. The progression of welding technologies often coincides with the development of novel materials, which in turn wields a substantial influence on the aerospace domain.

Furthermore, the trend towards automation within the welding industry carries noteworthy implications. By incorporating automation, the aerospace industry stands to gain more consistent and dependable results from welding processes. Given aerospace’s precision and reliability demands, this trend holds particular significance within this sector.

Could automated processes and robotic welding replace manual welding for refinishing components?
Yes, automated processes and robotic welding have the potential to replace manual welding for refinishing components, driven by several compelling reasons. One notable advantage is the consistency and precision offered by robots. They execute tasks with unwavering uniformity and high accuracy, resulting in superior-quality welds and virtually zero defects.

Efficiency is another compelling factor. Automated processes operate continuously without breaks, leading to higher productivity. Additionally, robots often outpace human workers in speed, further enhancing overall efficiency.

Safety considerations also favour the utilisation of robots. Welding involves inherent risks due to the generation of heat and intense light. Integrating robots in this context can significantly reduce potential hazards to human workers, promoting a safer working environment.

The upfront investment in robotic welding technology might be substantial from a financial perspective. Nonetheless, the increased efficiency and decreased labour costs can lead to significant savings over time.

However, it’s important to acknowledge that while robotic welding boasts numerous advantages, its suitability for all tasks may be limited. Complex or custom jobs still necessitate the skill and expertise of human welders. Thus, a hybrid approach that combines manual and robotic welding might present the most optimal solution across various cases and scenarios.

How is augmented reality being utilised to train and enhance the skills of welders?
Augmented Reality (AR) is on the rise within the welding domain, particularly for the training and advancement of welders, manifesting in various ways.

Firstly, AR enables welders to engage in virtual practice, honing their skills in a simulated environment before moving on to real-world tasks. This dual benefit conserves material costs while furnishing a secure, risk-free avenue for practice. Secondly, AR systems provide real-time feedback to welders, pointing out errors and suggesting avenues for improvement. This dynamic feedback loop expedites the learning curve and facilitates swift skill development.

Moreover, AR can simulate intricate or dangerous scenarios that might be challenging to replicate. This facet empowers welders to cultivate familiarity and confidence in managing challenging situations. Furthermore, AR can offer step-by-step visual guidance throughout welding, overlaying pertinent information onto the actual view. This proves especially advantageous for intricate or infrequently executed tasks.

AR’s capacity to enable remote learning and collaboration emerges as another asset. By harnessing AR technology, welders can partake in learning and collaborative endeavours from disparate locations, a particularly pertinent capability amid the ongoing pandemic and within organisations spanning multiple geographical areas. And it can help standardise training methodologies. AR aids in unifying training procedures, ensuring consistent and high-quality instruction for welders, irrespective of their geographical location.

The strategic integration of AR into training initiatives equips companies to enhance the proficiency of their welders in a more streamlined manner. Consequently, this integration promises to augment quality and productivity within welding practices.

What are the potential applications for cobots in welding processes within the aerospace industry?
Collaborative robots, often referred to as Cobots, are increasing in adoption across diverse industries, including aerospace, owing to their capacity to work harmoniously alongside humans with safety and efficiency in mind. Within the realm of welding processes specific to the aerospace sector, Cobots present a range of potential applications:

Precision welding: Given the demand for high-precision welding in aerospace components, Cobots stand poised to execute such tasks with remarkable consistency and accuracy, offering a solution for achieving meticulous results.

Repetitive tasks: Cobots tirelessly perform repetitive tasks, rendering them well-suited for the prolonged production runs often encountered in aerospace manufacturing.

Challenging locations: Cobots can be outfitted with specialised tools and programmed to navigate intricate spaces that might pose challenges for human welders, extending their reach to such demanding areas.

Quality control: By integrating appropriate sensors and programming, Cobots can inspect welds and other manufacturing facets, enhancing the assurance of superior quality and uniformity.

Training: Cobots can play a role in training scenarios, allowing new welders to gain hands-on experience while sidestepping potential risks of injury.

Flexible production: Cobots’ ease of reprogramming and adaptability renders them conducive for custom, low-volume production runs. This adaptability aligns well with the aerospace sector’s propensity for frequent changes in component specifications.

While Cobots hold promise for substantial benefits, their effective integration necessitates meticulous planning and thoughtful consideration. Aspects such as safety protocols, the necessity for human supervision, and the seamless assimilation of Cobots into existing workflows warrant deliberate attention. Nonetheless, a well-orchestrated approach positions Cobots as a valuable asset in the ongoing aerospace industry endeavour to augment efficiency, quality, and safety.

What factors have contributed to the recent advancements in automation for welding processes?
Following are some factors that have contributed to the recent advancements in automation for welding processes.

Improved technologies and equipment: Integrating cutting-edge equipment and technologies has been pivotal in automating welding processes. This encompasses the deployment of welding robots, sophisticated automated welding systems, and state-of-the-art welding tools.

Enhanced precision and accuracy: Automation has engendered a notable enhancement in the precision and accuracy of welding procedures. This, in turn, has yielded tangible improvements in weld quality, effectively curbing the occurrence of defects.

Improved productivity: Automation has emerged as a potent catalyst for elevated productivity and heightened efficiency in welding operations. This transformative effect translates into swifter welding durations and augmented production rates.

Augmented safety: Automation has ushered in improved safety protocols within welding processes. Automation has fostered a safer work environment by reducing workers’ exposure to hazards, effectively curtailing accidents.

Cost optimisation: Automation has engendered cost-cutting benefits within welding processes through several avenues. These encompass the reduction in manual labour requirements, the minimisation of errors, and the optimisation of production efficiency. Collectively, these contribute to multifaceted cost reductions.

In summation, the amalgamation of these diverse factors has catalysed the recent strides witnessed in automation for welding procedures and has also spurred advancements that permeate various welding dimensions.

What strategies can raise awareness among skilled workers to adopt automation in welding?
Raising awareness among skilled workers regarding the integration of automation in welding can be accomplished through a range of strategic approaches:

First, prioritise education and training by orchestrating workshops, seminars, and training sessions. These initiatives can elucidate the advantages of automation in welding, incorporating live demonstrations of automated welding procedures, hands-on experience with automated equipment, and presentations elucidating the impact of automation on productivity and safety.

Maintain a steady dialogue with workers regularly regarding the company’s automation plans. Employ channels such as newsletters, emails, meetings, and bulletin board postings to convey the organisation’s direction transparently. By fostering transparency, concerns and resistance can be mitigated.

Incorporate workers into the automation process as an involvement strategy. Seek their input on automation plans, engage them in testing and implementing automated processes, and encourage them to express their thoughts and reservations. This participatory approach fosters a sense of investment in the process, thereby diminishing perceived threats.

Assuage worker apprehensions through reassurance. Clarify that automation is intended not to supplant them but to augment their roles. Emphasise the continued value and indispensability of their skills, knowledge, and expertise, underscoring that while certain tasks may be automated, their contributions remain pivotal.

Promote upskilling as a proactive measure. Create avenues for workers to acquire new proficiencies related to automation. This encompasses training in operating and maintaining automated equipment and venturing into domains such as programming and data analysis. By positioning automation as an avenue for career advancement, the narrative shifts from job jeopardy to professional growth.

Highlight success stories as a persuasive tactic. Share instances of other enterprises or industries that have seamlessly adopted welding automation, delineating the tangible benefits they’ve reaped. These tangible examples crystallise the potential advantages of automation for workers, making the concept more real.

By deploying these strategies, organisations can effectively cultivate awareness and understanding among skilled workers regarding the integration of automation in welding. 

 

In an era defined by environmental consciousness and sustainability, managing water resources is paramount for industries across the globe. As the demands on freshwater sources intensify, manufacturing facilities face a dual challenge: meeting their water needs while minimising their environmental impact.

One of the fundamental challenges is the need for more data regarding contaminants in wastewater streams. In many instances, water treatment plants need more comprehensive information about the exact composition of their wastewater. Shardul Apte, Director of Design and Sales at Goldfinch Engineering Systems Private Limited – Evaporator Division, notes, “This data deficiency can result in system designs that fall short of effectively addressing the specific contaminants present.”

Moreover, mixing different wastewater streams can lead to the creation of new, previously unknown contaminants. These unexpected compounds can further complicate the treatment process, potentially rendering the existing systems ineffective. It becomes evident that adapting to these unforeseen challenges necessitates a flexible approach to wastewater treatment.

Traditional wastewater treatment systems are often designed based on specific data parameters, which may not align with the actual composition of the wastewater. This mismatch between design and reality underscores the importance of continuously monitoring and assessing wastewater quality. Apte’s insights highlight the critical need for innovative, data-driven solutions that can adapt to the evolving landscape of wastewater contaminants.

Sustainable wastewater treatment in manufacturing

Priyanka Khaire, Deputy Manager of Bioremediation at Organica Biotech Pvt. Ltd., noted, “The wastewater treatment industry is undergoing a transformation driven by a confluence of factors. From environmental concerns and stringent regulations to technological advancements and sustainability goals, the industry is evolving to meet the demands of a changing world.

One key driving force is governments’ imposition of stringent environmental regulations and compliance standards worldwide. These regulations compel industries to treat wastewater efficiently, ensuring that pollutants are removed to meet increasingly stringent water quality standards. The result is a push towards adopting advanced wastewater treatment technologies and processes.”

Global water scarcity concerns are another catalyst for change. Responsible water management practices, including reusing treated wastewater for non-drinking purposes, are becoming more prevalent. This not only conserves precious freshwater resources but also aligns with sustainability goals. Corporate Social Responsibility (CSR) initiatives push companies to prioritise sustainability and implement effective wastewater treatment solutions. Technological advances, such as advanced biological treatments and AI-driven optimisation, are revolutionising the industry by making treatment processes more efficient and effective.

Public awareness of environmental issues also drives industries to adopt eco-friendly wastewater practices. This growing ecological consciousness pushes companies to embrace sustainable solutions and reduce their environmental footprint. Urban population growth and increased industrial activities generate more wastewater, making searching for sustainable wastewater solutions even more critical.

Innovations in zero liquid discharge

Mandar Vaijnapurkar, Head of Drives Sales, Marketing & Services, India, at Danfoss, sheds light on innovative approaches to wastewater management. Vaijnapurkar highlights two promising strategies: Zero Liquid Discharge (ZLD) and Minimal Liquid Discharge (MLD). ZLD and MLD are gaining traction in wastewater management by aiming to eliminate or drastically reduce liquid waste leaving industrial facilities. These approaches prioritise the reclamation and reuse of water, aligning with sustainability goals. However, a historical challenge with ZLD and MLD has been their high energy consumption, particularly in the traditional thermal-based methods. Recent studies suggest that incorporating membrane-based processes can significantly reduce energy consumption by up to 75%. This advancement is a game-changer in making ZLD and MLD more energy-efficient and environmentally friendly.

Evolving environmental regulations

Changing environmental regulations plays a pivotal role in shaping wastewater treatment practices in manufacturing. These regulations drive the adoption of more efficient and sustainable technologies, as pointed out by our experts. Stricter rules, especially regarding pollution removal and water quality standards, push industries to adopt advanced treatment techniques. These evolving regulations encourage innovation in wastewater treatment, leading to the development of sustainable technologies capable of handling emerging contaminants effectively. Resource recovery from wastewater, inspired by many regulations, is rising. Technologies like anaerobic digestion are being used to turn organic waste into biogas, promoting a circular economy approach.

Regulations in water-scarce regions are driving advanced treatment for water reuse, such as membrane filtration and UV disinfection. Public awareness and community pressure further influence these regulations, encouraging the adoption of sustainable wastewater practices.

Solutions for diverse wastewater challenges

Wastewater treatment challenges are diverse and region-specific, influenced by factors like water availability, population density, and industrial activity, as noted by Priyanka Khaire. Technology providers are customising solutions to address these unique challenges. Technologies prioritise water reuse and resource recovery in arid and water-stressed regions where freshwater resources are scarce. Advanced biological treatment processes play a crucial role in efficiently purifying water for non-drinking purposes.

Densely populated urban centres face challenges related to high organic loads and pollutants from industrial and residential sources. Decentralised and modular treatment solutions effectively manage substantial wastewater volumes while ensuring compliance with strict environmental regulations. Agricultural regions grapple with pollutants from chemical fertilisers and pesticides. Specialised bioremediation technologies are essential for breaking down these compounds and restoring natural ecosystem balances.

Holistic approaches, combining advanced biotechnology, data-driven insights, and modular design principles, are necessary to tackle these diverse challenges. Customised solutions must align with regional regulations, resource availability, and community needs, ensuring that effective wastewater treatment benefits everyone.

Emerging Contaminants

Mandar Vaijnapurkar added, “Emerging Contaminants (ECs) are a growing concern in water sources worldwide. These micropollutants threaten biology and human health, with potential implications for the rise of antimicrobial-resistant bacteria.

Standard biological treatments often need to remove ECs from wastewater. Advanced oxidation processes, such as ozonation and visible light-activated photocatalysts, promise to eliminate most ECs from water sources effectively. This breakthrough is critical for safeguarding human health and preventing the spread of antimicrobial resistance.”

Sewage-to-water recycling

As global water consumption rises, manufacturers must consider sewage-to-water recycling as a viable and sustainable solution. A rapidly industrialising world has resulted in large volumes of wastewater being discharged into the environment daily, with only half of it being treated.

Untreated wastewater not only threatens water security and ecosystem health but also has a significant impact on greenhouse gas emissions. The greenhouse gas footprint of untreated wastewater is three times higher than that of treated wastewater. This underscores the urgent need for alternative wastewater treatment measures that recover usable water.

Integrating circular economy principles into wastewater treatment is a forward-looking approach that harnesses wastewater’s potential for resource generation. By promoting closed-loop systems and minimal waste, sewage-to-water recycling is becoming a vital component of sustainable water resource management.

Shardul Apte, Director – Design and Sales, Goldfinch Engineering Systems Private Limited – Evaporator Division
“Water treatment plants lack comprehensive information about the exact composition of the wastewater they are tasked with treating, making it one of the fundamental treatment challenges.”

Mandar Vaijnapurkar, Head of Drives Sales, Marketing & Services, Danfoss India
“The integration of circular economy principles in wastewater treatment is a forward-looking approach that harnesses wastewater’s potential for resource generation, promoting a closed-loop system for minimal waste and optimal resource use.”

Priyanka Khaire, Deputy Manager – Bioremediation, Organica Biotech Pvt. Ltd.
“Commitment to sustainable solutions should extend beyond technical innovation to include capacity building and community engagement, ensuring that effective wastewater treatment benefits everyone.”

In a realm shaped by rapid technological strides, the global robotic welding market is undergoing a profound metamorphosis, driven by the relentless advance of automation, training and environmental consciousness, underscoring the role of skilled welders in shaping a sustainable future.

In an era of rapid technological advancements, the global robotic welding market is undergoing a monumental shift driven by the relentless march of automation technology. A recent comprehensive report from Fortune Business Insight has illuminated the trajectory of this transformation, predicting that the market will catapult from its $5.80 billion valuation in 2021 to a staggering $9.76 billion by 2028. This ambitious growth is expected to be propelled by a Compound Annual Growth Rate (CAGR) of 7.7 percent during the forecast period spanning from 2021 to 2028.

The burgeoning potential of this market has been recognised by industry giants, new entrants, and Small and Medium Enterprises (SMEs). The field of welding, long considered a specialised craft necessitating skilled labour, spans industries as diverse as construction, manufacturing, automotive, shipbuilding, aerospace, oil & gas, railways, and even small-scale grill factories. The ubiquitous need for welders underscores their critical role in shaping our modern world.

Across the continents of Asia, Africa, and Eastern Europe, both developing and less developed countries contribute significantly to the annual pool of welders. However, the focus has shifted toward cultivating highly skilled welders capable of seamlessly adapting to multifaceted roles. While traditional methods like TIG (Tungsten Inert Gas) welding have been cornerstones in industries such as aerospace, the advent of MIG (Metal Inert Gas) synergic cure and robotic welding systems has ushered in a dynamic shift toward more efficient and adaptable techniques.

Aerospace industry and welding technology trends
The aerospace sector, known for its unwavering commitment to precision and safety, is seeing a compelling fusion of advanced welding techniques with the trajectory of technological evolution. As Dr. T.J. Prasadrao, Executive Director at D & H Secheron, attests, this amalgamation is set to yield more consistent and dependable welding outcomes. This is particularly pivotal in an industry where even a minuscule flaw can have dire consequences.

One of the primary vehicles driving this transformation is automated processes and robotic welding. Robots with unwavering consistency and precision have emerged as quality welds with near-zero defects. Their tireless work ethic and ability to operate with high accuracy and speed position them as formidable assets in augmenting efficiency. Nevertheless, while robots have proven their mettle, they may not be a panacea for welding needs. Complex tasks and custom jobs still require the skilled human touch, necessitating a hybrid approach seamlessly integrating manual and robotic welding.

Empowering welders through virtual horizons
In a world where molten metal and sparks have long defined the art of welding, a quiet revolution is unfolding, driven by cutting-edge technology. As the sun sets on traditional methods, Sumon Mitra, the Director of Sales at Cloos India Welding Technology Private Limited, envisions a new dawn for skilled workers. A series of welding robotic seminars, robotic courses, and hands-on practical sessions will shatter the boundaries of conventional training.

But this is only the beginning. Rituraj Bose, the Honorary Secretary General of the Indian Institute of Welding, envisions a greener future for the welding industry. With conviction, he champions the integration of Augmented Reality (AR) into the training curriculum. “Virtual and augmented reality,” he asserts, “hold the key to unlocking environmentally friendly welding processes.”

In this new world, trainee welders wield AR headsets. Virtual tools and materials replace their tangible counterparts, sparing the environment from the ecological toll of traditional training methods. As they immerse themselves in a simulated welding environment, these future welders find themselves free from the constraints of real-world consequences. AR becomes their mentor, a tireless guide through the intricacies of the craft. It watches their every move, casting a watchful eye on their progress. When errors occur, AR nudges them onto the right path, offering real-time insights for improvement. This symbiotic dance between technology and trainee expedites skill development, carving a faster path to mastery.

AR turns geographical boundaries into mere lines on a map. Welders from around the globe converge in virtual spaces, united by their pursuit of excellence. Training methodologies become standardised, ensuring every aspiring welder receives the same high-quality instruction, regardless of where they stand on Earth. And the very essence of welding is that these AR-powered simulators accurately replicate the experience. The future of welding is here, and it’s not just about machines; it’s about empowering welders to reach new heights through the virtual horizon.

Cobots in aerospace
Within the aerospace sector’s unique welding challenges, Collaborative Robots or Cobots shine as game-changers. These robots are meticulously designed to reduce programming complexities and manoeuvre through intricate spaces. Often replete with intricate shapes and contours, aerospace components pose challenges for even the most skilled human welders. Armed with specialised tools and programmed acumen, Cobots can easily navigate these spaces, extending their reach to the most demanding areas. Integrated sensors and programmed inspections further bolster their contribution to superior quality and consistency.

Training and environmental consciousness
Amidst these technological leaps, it’s imperative to spotlight the indispensable role of skilled workers. Automation doesn’t intend to replace them; it’s designed to amplify their capabilities. Workshops, seminars, and training sessions have emerged as critical platforms for raising awareness and understanding among skilled workers. These initiatives demonstrate automation’s advantages, offer live demonstrations and hands-on experiences, and enlighten attendees about the impact of automation on productivity and safety.

As the welding landscape evolves, the need for continuous training becomes even more pronounced. Industries are actively seeking proficient welders who are adept in environmentally conscious practices. The long-term benefits of investing in training centres are becoming evident, facilitating cost savings, reduced training expenses, and democratising access to welding education.

Safeguarding the future
In an age where the sparks of innovation illuminate the welding landscape, a pressing question looms: Where are tomorrow’s skilled welders? Amid the allure of air-conditioned malls and the allure of food delivery gigs, some might dismiss the art of welding as a relic of the past. Yet, as the global environment grapples with pollution’s relentless advance, the role of proficient welders takes on new urgency.

In a world where welding is no longer confined to mere craftsmanship but blends seamlessly with science and technology, the call for continuous training echoes with newfound significance. Practical experience, nurtured within technology centres, has become the compass guiding aspiring welders towards becoming adept professionals. In a realm marked by advancements, being relevant means adapting to change and refining skills in step with evolving welding processes.

Amidst this transformation, a larger narrative unfolds. The planet groans under the weight of pollution from myriad human activities – from towering industries to rumbling vehicles, even down to the sparks of welding itself. Industries worldwide strive to temper their environmental impact through countless measures. Yet, the welding deserves dedicated consideration.

It’s within this evolving landscape that the concept of continuous training takes root. While the initial costs may loom large, particularly in developing nations, the long-term dividends are undeniable. As training expenditures diminish, students can seize opportunities previously beyond reach, bridging the global chasm between the demand and supply of skilled welders.

In essence, the arc of change beckons welders to embrace the dual roles of custodians of tradition and pioneers of innovation. It calls industries to view training as an investment in a sustainable future, where skilled hands wield torches that shape progress. And it implores the world to see that while technology races forward – its very soul is still rooted in the hands of those who meld metals, forging the structures of tomorrow.

Sumon Mitra, Director- Sales, Cloos India Welding Technology Private Limited.
Skilled workers can be invited into the different welding robotic seminars, robotic courses & practical sections to increase awareness.

Dr. T.J. Prasadrao, Executive Director, (Technical), D&H Sécheron.
Automation has become a potent catalyst for elevated productivity and efficiency in welding operations, translating into swifter welding durations.

While exploring, Amit Goel, Assistant General Manager, Zonal Head – North, Ace Micromatic, shared his insights about their innovative products, international expansion, support infrastructure, automation, and market presence in the machine tool industry.

Please share the key highlights and achievements from Ace Micromatic’s recent participation in the DMTX Expo?
Ace Micromatic showcased its Turning, Milling, Grinding, and IioT solutions at the DMTX Expo. The star attractions at our exhibit were the Sliding Head and Compact CNC Lathe, the high-speed Drill Tap Centre, which serves as an outstanding import substitute, and a state-of-the-art machine designed specifically for Die and mould manufacturing. Additionally, we proudly presented our impressive array of 3D-printed components.

In a remarkable achievement, Ace Micromatic is delighted to announce that our Group Company, AMACE, played a pivotal role in printing the National Emblem on the Pragyan Rover Wheel of Chandrayaan-3.

How can SMEs boost economic growth and productivity through technology and skilled workforce strategies?
Small and Medium Enterprises (SMEs) are undeniably pivotal drivers of a nation’s economic growth, providing employment opportunities to a significant portion of the workforce. To bolster their potential, SMEs can strategically invest in cutting-edge technology, recruit highly skilled personnel, and provide ongoing training tailored to current requirements. Leveraging digital technology can further amplify their overall productivity and operational efficiency.

Can you share the company’s approach to innovation and product development in alignment with market demands and future trends?
Ace Micromatic showcased an array of products at IMTEX, encompassing a 3D printing machine, versatile multitasking equipment, gear manufacturing solutions, a 24,000 rpm Drill Tap Center tailored for the electronics sector, an expanded VMC for precision pattern creation, robust Double Column machines, and a VTL incorporating an innovative chuck changer concept. Additionally, we have worked on an enlarged VTL, CBN Grinding machines, and multitasking grinding machinery. Our other innovations extended to nano machining involving glass and various pioneering IoT solutions. We are working associated with many ongoing projects set for imminent commercialisation, aligning our product development with evolving market needs and future trends.

How does your nationwide presence and feedback system support product quality and sustainability?
Benefiting from an extensive nationwide presence, our company maintains a robust feedback system that provides valuable insights into the performance of our products across India. This involves conducting Pareto Analyses for each product, leading to continuous refinements in our manufacturing processes and Bill of Materials (BOP) components. Our commitment lies in ensuring our products’ enduring quality and sustainability in the long term.

How does Ace Micromatic’s IioT integration benefit customers?
All our machines are fully compliant with the latest IoT standards. These machines seamlessly connect to the network in real time, offering invaluable feedback to users and empowering them to take prompt, tailored actions as required. Our dedicated IioT team hails from our affiliate company, AmiT (AceMicromatic Intelligence Technologies Ltd.), consistently enhancing this platform. Our roster of satisfied customers features achievements in areas such as Overall Equipment Effectiveness (OEE), EShopx integration, Traceability, Auto Offset Correction, Process Capability, ANDON systems, and more.

How does AMG differentiate itself through innovation in IoT, automation, and its extensive support infrastructure in India?
In today’s landscape, IoT has become imperative. The topic of digitisation is on everyone’s lips, including the Indian government, as we envision a digitally-driven future. AMG has been a pioneer in this field for over a decade, boasting numerous success stories in India and overseas. We’ve established a dedicated IoT support team to cater to our customer’s needs.

Furthermore, we’ve supplied many machines with various automation technologies, encompassing robotics, gantry systems, and chute automation. Our “In Field Automation” team possesses the expertise to implement these solutions directly on previously supplied AMG machines tailored to specific components and processes. Our Strategic Service unit continually engages in innovative enhancements for machines already deployed in the field.

With a vast presence across India, comprising over 70 offices and a formidable team of 700+ professionals dedicated to customer support, along with 8 Tech Centers, National and Regional Warehouses for efficient spare parts support, and AMG Value Centers for machine reconditioning and buy-back services, we distinguish ourselves from competitors. Our motto is simple yet powerful: “ALL you Need in Machining.”

What are Ace Micromatic’s international expansion plans and export growth targets by 2030?
Ace Micromatic has established offices in China and Germany. With Ace Micromatic International’s (AMI) formation, we are now intensifying our international market efforts. Looking ahead, significant expansion plans are in the pipeline, with a strong emphasis on collaborating closely with channel partners. The ambitious target is to achieve a substantial 20% export growth by 2030.

Subbu Venkatachalam, Head of Marketing, Carborundum Universal Limited, asserts that the ‘Make in India’ initiative has propelled India’s aerospace and defence sector leading to decreased reliance on defence imports, positioning India as an active contributor on the global stage while brisking its position as a hub for indigenous production and innovation.

How is CUMI’s integration of cutting-edge materials and technologies contributing to the transformation of the aerospace and defence sector?
The aerospace and defence sector is significantly transforming due to advancements in material science, nanotechnology, and engineering methods. These breakthroughs are causing a revolution in various aspects, such as personal protection gear, safeguarding vehicles, unmanned aerial vehicles (UAVs), and missile systems. This, in turn, is leading to improvements in overall performance, longevity, and strategic capabilities.

CUMI is at the forefront of this transformation, offering comprehensive solutions that integrate cutting-edge materials and technologies. This contribution is instrumental in the development of more efficient defence solutions that effectively tackle the evolving challenges posed by modern warfare:

Advanced Ceramics: CUMI’s exceptional ultra-fine silicon carbide powders and lightweight ceramics redefine personal armour and vehicle protection. These innovations adhere to stringent global standards such as the NIJ ‘Level IV’ and provide ballistic solutions for armoured vehicles, achieved through hybrid composites and ceramic tiles.

Composite materials for UAVs: CUMI’s Carbon Fibre Reinforced Polymers are enhancing the structural integrity of UAV airframes, consequently elevating flight performance, operational range, and payload capacity. Moreover, the incorporation of graphene-reinforced CFRP components has the potential to transform the construction of structural elements in drones completely.

Refractories for harsh environments: CUMI supplies aerospace components with refractory solutions that ensure consistent and reliable performance, even when exposed to extreme temperatures. This includes applications in investment casting and thermal protection shields.

Innovative material offerings: CUMI Minerals actively produces high-performance minerals like alumina, silicon carbide, and graphene-infused solutions. These materials significantly enhance the robustness and efficiency of defence equipment.

Precision manufacturing: CUMI’s expertise in bonded and super abrasives, precision machining, and advanced synthetic metalworking fluids is pivotal in optimising manufacturing processes and enhancing overall efficiency.

In conclusion, CUMI’s diverse suite of solutions effectively leverages these innovations to create more potent defence strategies capable of addressing modern warfare’s complex and evolving landscape.

What primary factors are contributing to the growth of drones in India’s aerospace and defence capabilities?
The rising popularity of drones within aerospace and defence capabilities has been driven by strategic policies, technological advancements, and changing operational requirements. The ‘Make in India’ initiative has encouraged domestic production, facilitated partnerships, and strengthened self-sufficiency in the aerospace and defence sectors. The Ministry of Civil Aviation (MoCA) has introduced updated drone regulations, simplifying UAV operations by establishing clear frameworks.

Drones showcase remarkable operational adaptability, fulfilling various roles ranging from surveillance to precise military actions. They are crucial in enhancing border security along India’s borders, providing aerial coverage over difficult terrains and remote regions. Technological progress in drone capabilities, such as extended flight times, improved payload capacities, and advanced sensors, amplify their contributions to defence efforts. This, in turn, enables the execution of intricate missions and reinforces strategic defence operations.

The emphasis on promoting self-reliance and diminishing dependence on imports aligns with India’s pursuit of achieving strategic independence in defence matters. The nation will strengthen its defence preparedness by fostering the growth and production of domestic drones. This approach will allow India to respond effectively to emerging threats, adjust to evolving operational requirements, and maintain substantial control over its defence capabilities.

How is the Make in India initiative impacting the aerospace and defence industry in India
The impact of the ‘Make in India’ campaign on India’s aerospace and defence sector has been profound, ushering in a transformative era marked by self-reliance and domestic manufacturing. The Ministry of Defense is diligently steering modernisation by phasing out outdated equipment. This is evident through adopting long-term perspective plans, capability roadmaps, and strategies for capital acquisition. Notably, the Indian aerospace and defence industry, valued at approximately US$ 9.7 billion (Rs. 80,000 crores) in the fiscal year 2019-20, has received a significant boost from the growing involvement of the private sector, contributing around US$ 2.05 billion (Rs. 17,000 crores).

The vision of ‘Make in India’ has materialised through establishing two defence corridors in Uttar Pradesh and Tamil Nadu. These corridors have strengthened domestic manufacturing capabilities and promoted collaborative endeavours across different branches of the armed forces.

The substantial growth in defence exports, marked by an impressive 334% increase over the past five years, underscores a notable shift towards self-sufficiency. This move towards a defence policy centred on domestic manufacturing is supported by a significant allocation of US$ 18.65 million (Rs 1.52 lakh crores) for capital investments in the FY2022-23 budget. This allocation highlights India’s commitment to nurturing domestic research and development ecosystems.

From a broader perspective, the ‘Make in India’ initiative has propelled India’s aerospace and defence sector towards a strategic autonomy and expansion trajectory. This path will lead to decreased reliance on defence imports, positioning India as an active global contributor while fortifying its position as a hub for indigenous production and innovation.

Please elaborate on CUMI’s Composites manufacturing and testing of composites.
CUMI’s Composites Manufacturing Division boasts a legacy that spans more than five decades, characterised by its expertise in the design, manufacturing, and rigorous testing of composites. This division serves as a testament to CUMI’s unwavering dedication to cutting-edge technology, particularly evident in its significant contributions to Unmanned Aerial Vehicles (UAVs).

The heart of this division is CUMI’s state-of-the-art facility, deliberately designed to uphold a dust-free environment, ensuring the precision and integrity of composite manufacturing processes. This facility is equipped with a diverse range of advanced techniques covering the entire composite fabrication spectrum. Techniques such as vacuum infusion and bagging create resilient and robust composite structures. Additionally, the division’s capabilities are enriched through methods like resin transfer moulding (RTM) and pultrusion, enabling the production of intricate and high-performance components.

CUMI’s commitment to innovation is evident in its embrace of cutting-edge technologies, including filament winding, a fundamental technique for crafting intricate composite structures. This comprehensive array of manufacturing methods is closely tied to developing and creating Carbon Fiber Reinforced Polymer (CFRP) components. These components are renowned for their remarkable strength-to-weight ratio, durability, and fatigue resistance. Currently, CUMI is actively engaged in the development of CFRP components reinforced with nanomaterials, a breakthrough that holds the potential to revolutionise the aerospace sector by introducing lighter and stronger structural elements.

 The division’s achievements extend beyond its manufacturing capabilities, exemplified by its notable TUV-Nord EN9100:2018 certification. This certification is awarded for ‘Design, Development, and Manufacturing of Structural Composites for Aerospace Applications.’ This credential is a testament to the division’s strict adherence to exacting aerospace standards, positioning it as a reliable partner in creating advanced composite solutions for the aerospace industry.

What is the importance of upskilling to harness opportunities presented by automated manufacturing?
In the evolving landscape of manufacturing driven by automation, a skilled workforce is essential to capitalise on the benefits. Experienced experts can effectively manage and oversee automated systems, guaranteeing smooth production operations and adherence to stringent quality benchmarks. Their specialised knowledge allows them to diagnose technical issues and optimise automated procedures, ultimately increasing efficiency and minimising periods of inactivity.

Furthermore, enhancing the skill set of workers empowers them to adeptly embrace emerging technologies, facilitating innovation and the integration of cutting-edge solutions. Consequently, prioritising upskilling holds significant importance within the manufacturing sector. To illustrate, 3D printing is a future-oriented manufacturing process across various industries. By implementing training initiatives to enhance the workforce’s skills, the existing gaps in expertise can be addressed, expediting the integration of this forward-looking technology. This, in turn, ensures that 3D printing can realise its full potential. Upskilling programs play a pivotal role in retaining experienced manufacturing professionals and driving the advancement of 3D printing’s industrial applications.

 

 

The aerospace and defence manufacturing sector has taken centre stage in India’s quest for self-reliance and advanced capabilities. This article explores India’s rapid growth in defence manufacturing, technological advancements, the role of AI, cybersecurity concerns, R&D support, technology transfer dynamics, nanomaterials, supply chain challenges, and the critical impact of 3D printing and additive manufacturing. 

The importance of self-reliance and bolstering domestic manufacturing capabilities is evident in the current global context, particularly given ongoing conflicts worldwide. India is well-positioned in this regard, attracting significant investments. The country’s defence manufacturing sector is valued at one lakh crore and is expected to reach 1.75 lakh crore within two years. This rapid growth aligns with the opportunity to integrate advanced technologies such as automation and 3D printing, especially as Original Equipment Manufacturers (OEMs) gradually embrace these innovations.

Self-reliance
India’s efforts to bolster self-reliance, particularly in the aerospace sector, are commendable. These endeavours include investing in research and development, expanding the skilled workforce, improving infrastructure, and fostering public-private partnerships. Dr. C. V. S. Kiran, Lead – R&D and Strategy, Skyroot Aerospace, added, “The introduction of innovative regulatory reforms, as seen in the space sector, and export incentives further fortify this drive toward self-sufficiency. India’s involvement in international projects enhances its global reputation. While cybersecurity concerns exist, the nation is actively addressing them. Efforts are also underway to establish specialised excellence hubs and expand ecosystems in various domains, including aerospace and defence, focusing on securing capital access.”

According to Maruthi Amardeep, Co-founder and CEO of BluJ Aerospace Pvt. Ltd., India has a long history of manufacturing, but it’s typically been in lower-tech sectors. However, the Make-in-India campaign has changed this perception. It’s about more than just serving the domestic market; the world views India differently. Every manufacturing company, OEM, or design house we encounter is showing some commitment to Make-in-India, whether it’s 10% or 5% of their operations. More than just creating new manufacturing capabilities, Make-in-India has ignited a fresh wave of enthusiasm and a clear direction for the country: to engage in advanced manufacturing sectors. Aerospace is a prime example of this shift.

India’s journey towards self-reliance is still evolving in the field of unmanned aerial vehicles and drone technology services. The government plays a significant role by organising events like Drone Mahotsav and expos, which serve as valuable platforms for networking and forging connections both within the country and internationally, propelling technology advancements. Moreover, government bodies, including the Department of Science and Technology, provide funding and mentoring opportunities.

The Role of AI in Education
AI-based products are valuable tools for expediting product development. However, it’s crucial to recognise that the human brain remains a vastly more powerful resource. Combining human intellect with AI technology is critical in today’s rapidly evolving AI landscape.

In sectors like defence and aerospace manufacturing, there’s a level of trust that can be placed in AI-based products, but more than full reliance on AI is needed, as per Dr Kiran. The excitement around AI has led many students to pursue AI and computer science, sometimes at the expense of core scientific and engineering disciplines. This trend could have significant consequences in the coming years. It’s essential to strike a balance, ensuring that the next generation is equipped with the broad knowledge and skills required to address future challenges. Relying solely on AI without a strong foundation in traditional fields of science and technology can have far-reaching implications for the country’s future generations.

Cybersecurity Concerns
The issue of importing technology is a significant concern. Nowadays, in high-tech industries globally, companies often wrap their intellectual property around software and electronics while being more open to outsourcing mechanical components. This practice poses a threat.

Shinto Joseph, Director – South East Asia Operations, LDRA Technology, adds that self-reliance has to be prioritised in this domain. In scenarios where we might need to use a system in a specific context or against a particular country, the entity supplying the system could restrict its use. Furthermore, there’s the risk that the system may not function correctly in certain conditions, such as within a GPS environment. This underscores the importance of expanding our capabilities and fostering indigenous development in these areas, especially in cybersecurity.

Dr Kiran adds that the landscape of cyberattacks is becoming increasingly turbulent. It’s a complex place to navigate. Even the simplest things can have severe consequences. For instance, a seemingly innocuous email can lead to a web of malicious links, causing significant discomfort to an individual or civilian who may lose money. The impact is even more profound for startups and budding enterprises. They invest tremendous effort and resources into their work, often losing valuable intellectual property and sensitive data in the face of cyber threats.

In the defence sector and critical infrastructure, it goes far more profound. Most cyberattacks target the firmware level and communication layers, often bypassing conventional antivirus tools. This misperception of being secure when antivirus software does not detect threats is a concerning issue. Attackers could be operating below these layers, potentially compromising sensitive networks. Sensitising individuals to this broader and more complex threat landscape is imperative, especially in defence. For us, operating in the realm of unmanned aerial vehicles, security goes beyond safeguarding our company’s intellectual property. It’s about ensuring the security of direct communication with the machines themselves. This aspect poses an even more significant threat than protecting our intellectual assets.

R&D
The aerospace industry is experiencing significant support from research and development, particularly from the Department of Science and Technology. Krithiga Sreenuvasan, Director (Operations), Jet Aerospace, notes that this support includes funding and guidance on the entire manufacturing process. Apart from financial assistance, they’re helping individuals who may need more entrepreneurial experience to navigate the path from skilling to mentoring and ultimately establishing successful businesses. This comprehensive government support is poised to drive substantial success in R&D for the aerospace and defence sectors in the years ahead.

Technology transfers
Global technology transfer has surged amid ongoing conflicts and geopolitical tensions. It manifests in two primary forms: intergovernmental transfers between nations and private entities collaborating with other private organisations.

Dr. Kiran said, “In aviation, transferring technology encounters barriers like restrictions on engine types and regulatory obstacles. Engine specifications often determine transfer feasibility. U.S. regulations, guided by bilateral treaties, can either facilitate or hinder transfers based on historical agreements and technology denials. These factors directly influence what technology can be shared and used in a country’s aerospace domain.”

The crucial question revolves around the value of technology transfer efforts. India has received significant support from Europe, Russia, and France, particularly in aerospace. Despite past technology denials, notably from the U.S., India now contributes substantial technologies globally. This shift highlights changing technology transfer dynamics and India’s growing role in the global technology landscape. We must return to our roots, harness our capabilities, and leverage available resources. Setting long-term objectives, motivating our people, and fostering self-reliance should be our priority. Collaboration with foreign partners is welcome, but our aim should be self-sufficiency while remaining open to sharing technology with others in the long run. Just as we’ve faced limitations from other countries, we should be ready to assist and share our expertise to help others.

Nanomaterials for aerospace applications
Nanomaterials have garnered significant attention over the past decade and a half, although caution should be exercised in selecting practical and viable applications. While nanomaterials show promise at the laboratory scale, transitioning them to large-scale production poses substantial challenges, particularly in achieving consistent quality and reliability, which are crucial for industrial applications like aerospace.

Scaling up nanomaterials to meet stringent reliability standards, such as 95%, 96%, or even 99.99%, is exceptionally demanding, suggested Mr Amar. Moreover, even if achievable, the actual benefits they offer raise questions due to their associated downsides. There are specific applications, especially in electric and thermal conductivity, where nanomaterials find utility, but primarily in small components.

Bringing any application from a laboratory scale to industrial fruition is time-consuming. In the realm of materials, the industry’s mastery, particularly in metals, has evolved over decades, drawing from ancestral knowledge. Similarly, the field of nanomaterials is relatively new for industrial production and achieving reliable and reproducible products, especially on the scale of sensors or batteries, take a substantial amount of time and development.

Supply chain for raw material
Sharing his personal experience, Mr Amar adds that aircraft manufacturing companies face daily challenges in building aircraft and rocket systems, particularly in establishing robust supply chains. The key to overcoming this lies in adopting a long-term perspective. Many large corporations in the country often have short-term views, which they can justify for their reasons. However, to address this issue effectively, a few companies, whether big or small, need to commit to a genuinely long-term outlook, which can range from 10 to 15 years or more. If successful, these companies can significantly transform the landscape by building reliable supply chains. It requires a collective effort with a long-term vision.

In simpler terms, the production capacity of these items can be increased. However, it’s essential to recognise that behind this statement lies a complex reality. Mr Shinto noted that to achieve this, numerous startups and companies must step up and establish aerospace or defence-quality production capabilities that meet the stringent quality and specification requirements. The process takes time and effort and involves fostering a thriving ecosystem of indigenous startups in these sectors.

3D Printing
3D printing offers substantial time-saving advantages. It requires rigorous examination and adherence to critical qualification standards at various levels. Ms Kritiga added that in drone technology, 3D printing plays a vital role. When it comes to producing drones or UAVs in India, the challenge is sourcing components domestically. However, 3D printing is a game-changer in achieving self-reliance. It allows the manufacture of frames, supporting structures, and even propellers required for drones and UAVs.

While 3D printing is widely utilised across sectors like aerospace, defence, and strategic industries, a critical issue remains: the extent to which these 3D printers are domestically manufactured is limited. Achieving self-reliance in this aspect is crucial. Whether it’s in polymeric or metal/alloy additive manufacturing, there’s a pressing need to develop the capability to produce our 3D printers shortly. This move would significantly reduce our dependence on imports and drive our self-reliant development in this technology.

Additive manufacturing
In contrast to subtractive manufacturing, which involves significant material wastage, additive manufacturing, like 3D printing, generates less waste, especially regarding support structures. Additionally, additive manufacturing results in fewer components, reducing the likelihood of failures. As a result, both metal and polymer additive manufacturing have been gaining prominence.

By 2030, the metal additive manufacturing sector is projected to be worth around 50.6 million US dollars. This field is witnessing a significant surge because it provides the flexibility to 3D print materials in various customisable forms, adapting to evolving research or company needs. However, these advantages require meticulous examination and thorough characterisation, both before, during, and after the printing process.

Upskilling
Upskilling has become critical across industries, particularly transitioning from traditional to digital and software-driven systems. This is evident in sectors like automotive, where cars have evolved into software-defined machines. The aerospace and defence industries are following a similar trajectory, with a shift towards electronics and software. To meet these changes, reskilling the existing workforce is essential. Instead of discarding experienced employees, there should be a concerted effort to reskill them. This might require collaboration between the government and private agencies to invest in reskilling programs. Aerospace is unique because older individuals can continue working in the field, making it a lifetime opportunity for those passionate about it.

Shinto Joseph, Director – South East Asia Operations, LDRA Technology

“To achieve self-reliance, startups and companies must step up and establish aerospace or defence production capabilities that meet the stringent quality and specification requirements.”

Maruthi Amardeep, Co-founder and CEO, BluJ Aerospace Pvt. Ltd.

“The make-in-India campaign has changed the perception of India’s presence in lower-tech sectors. It has evolved where the focus is not just on the domestic market; the world now views India differently.”

Dr. C. V. S. Kiran, Lead – R&D and Strategy, Skyroot Aerospace

“Whether it’s in polymeric or metal/alloy additive manufacturing, there’s a pressing need to develop the capability to produce our 3D printers shortly.”

Krithiga Sreenuvasan, Director (Operations), Jet Aerospace
“This comprehensive government support is poised to drive substantial success in R&D for the aerospace and defence sectors in the years ahead.”

Prashant Sinha, Head of Marketing, WIKA India, talks about the precise engineering that meets data-driven insights in the aerospace realm. Aerospace instrumentation and control systems have emerged as the backbone of modern aviation that withstands extreme conditions, while data acquisition empowers predictive maintenance, ensuring safety and innovation in aviation.

What is the role of instrumentation and controls in the aerospace industry?
Instrumentation and controls are crucial in the aerospace sector, as they are responsible for collecting, overseeing, and processing data about diverse factors and circumstances during flight. These setups ensure aerospace crafts’ secure and effective functioning by delivering real-time information to pilots and engineers, thus empowering them to make well-informed choices and modifications. They play a significant role in flight control, navigation, guidance, and overall craft performance. These setups are integrated into various technologies, encompassing sensors, actuators, avionics, and communication networks, to closely monitor critical variables such as altitude, velocity, temperature, and fuel levels. These technological advancements also enhance awareness of the surroundings, increase safety, and curtail fuel consumption. In the aerospace domain, instrumentation and controls are indispensable for achieving reliable and accurate operations.

What are some of the key instruments and sensors used in aerospace applications?
Various instruments and sensors are employed in the aerospace sector to gauge and supervise critical parameters. These encompass temperature gauges, pressure detectors, and fuel flow gauges, among other examples. These tools facilitate accurate manoeuvring, management, and performance tracking of aerospace crafts. On a global scale, instruments and sensors have become pivotal in multiple aerospace applications, delivering essential information about altitude, velocity, orientation, and position.

Some of the WIKA products used in the aerospace industry are:

• Force transducers for electric actuators and drives to help make air travel more sustainable
• Pressure transducers for jet engines’ ICE detection monitors
• Aerospace load pins for a spacecraft’s flight control system
• Direct drive pressure gauges for aerospace and military oxygen systems
• A battery-free passive RFID wireless sensing device to easily check an aircraft’s tire pressure
• A wireless temperature sensor that can withstand temperatures from –40°F to 257°F (–40°C to 125°C).

How are control systems utilised in aerospace vehicles for flight control, navigation and guidance?
Control systems within aerospace vehicles are vital for upholding stability, guiding flight, and ensuring precise navigation and direction. Some of the key control systems that optimise the functioning of an aircraft encompass:

Airflow sensors: These instruments gauge airspeed and orientation, delivering essential insights into aerodynamic analysis, engine efficiency, and flight control systems. They play a crucial role in guaranteeing aircraft and spacecraft’s secure and efficient functioning.

Temperature monitors with switch contacts: In flight settings, these devices oversee temperature thresholds in critical components such as engines. Once the temperature surpasses predetermined limits, these switches activate warning signals, averting overheating. This mechanism ensures optimal performance and safety in aerospace systems.

Pressure sensors: These are integral to aircraft for assessing altitude, computing airspeed, and managing cabin pressure. Their presence enables precise altitude determination, a pivotal factor in navigation and approach. Moreover, they contribute to maintaining safe cabin pressurisation across different altitudes.

WIKA offers an extensive array of temperature gauges and pressure switches tailor-made for aerospace applications. These sensor-driven devices anticipate temperature variations and incorporate mechanisms that prompt preemptive actions and trigger alarms during pressure surges. Their efficacy is particularly pronounced in dynamic environments, ensuring continuous safety throughout the operational process.

How do aerospace instrumentation and control systems handle extreme environmental conditions, such as high temperatures, vibrations and pressure?
Aerospace instrumentation and control systems are intricately designed and engineered to endure and perform efficiently within extreme environmental situations. They are crafted to withstand high temperatures, vibrations, pressures, and other demanding factors encountered during activities like space travel, flights at high altitudes, and re-entry into the atmosphere. Specialised materials, coatings, and isolation techniques are employed to shield delicate components from these conditions and uphold their operational integrity and dependability.

Materials resistant to high temperatures, heat shields, and cooling mechanisms are employed to prevent excessive heating. Methods to dampen vibrations and absorb shocks are implemented to counteract mechanical strains. Enclosures sealed against pressure are also utilised to shield components from elevated pressures, and sophisticated calibration algorithms are applied to uphold accuracy within these challenging settings.

These combined strategies empower aerospace systems to function flawlessly amidst elevated temperatures, vibrations, and pressures, ultimately ensuring the safety of both the flight and the crew under these demanding circumstances.

What are the typical data acquisition and analysis techniques used in aerospace instrumentation?
Data acquisition in aerospace instrumentation involves collecting information from diverse sensors and instruments installed on the aircraft. Subsequently, this data undergoes processing, examination, and interpretation to yield insights into the vehicle’s overall health, safety, and performance.

Advanced sensors collect various data points, including temperature, pressure, acceleration, and more, to comprehend flight conditions and enable real-time monitoring and analysis. Cutting-edge methodologies for data analysis, encompassing signal processing, statistical evaluation, and machine learning, are utilised to derive meaningful trends and identify potential concerns that warrant further exploration and enhancement. This process plays a pivotal role in the predictive maintenance of the aircraft, ultimately amplifying its safety.

The combined data acquisition and analysis activities constitute the foundation of aerospace instrumentation, allowing engineers to refine systems, ensure safety, and stimulate innovation within the aviation industry.

How do fault detection and redundancy play a role in aerospace instrumentation and control systems to ensure reliability and safety?
In aerospace instrumentation and control systems, ensuring the dependability and safety of the vehicle within challenging settings necessitates a strong focus on identifying faults and incorporating redundancy. Incorporating backup functionalities through redundant sensors and control systems is a crucial measure to counteract failures. This involves duplicating vital components like sensors and processors, guaranteeing uninterrupted functionality even when one element experiences a malfunction. Algorithms for fault detection are deployed to oversee the system’s operation, activating appropriate responses upon identifying anomalies or glitches. This approach minimises the likelihood of accidents and bolsters the system’s overall resilience. These technologies are pivotal in maintaining the optimal performance of an aircraft, averting potential calamities, and ensuring the well-being of both the crew and the vehicles.

What are the latest trends for correction and predictive maintenance in aerospace applications?
The aerospace industry has made great strides with technological advancements in correction and predictive maintenance. Some of the key areas that are making major progress are:

• Enhancing aircraft safety using machine learning algorithms to enable precise anomaly detection and fault prediction
• Preventing potential issues, minimising downtime and enhancing safety with proactive maintenance strategies
• Leveraging data analytics to forecast component failures, optimising maintenance schedules and resource allocation with robust predictive maintenance
• Receiving continuous insights into equipment health and facilitating timely interventions with real-time monitoring and diagnostics through advanced analytics.

These technologies are reshaping how maintenance is conducted in aerospace, ensuring streamlined operations, cost savings, and increased reliability by leveraging the potential of data-driven insights.

Velo3D launches Season 2 of its “Laser Focused” podcast, offering deep insights from engineering innovators. Hosted by Renette Youssef, it explores their challenges and strategies for success.

Velo3D, a renowned leader in metal additive manufacturing technology, has kicked off the second season of its widely acclaimed podcast, “Laser Focused.” This podcast, initiated in 2022, offers an engaging platform for conversations with trailblazers from diverse industries. Hosted by Renette Youssef, Chief Marketing Officer at Velo3D, the show delves into the intricate world of engineering, discussing the challenges faced and the strategies employed to overcome them.

“In the world of engineering, it’s common to hear about the end results achieved by successful entrepreneurs. However, we rarely get to uncover the obstacles they confronted on their journey and the invaluable insights that led to their triumphs,” remarked Renette Youssef. “Through in-depth, personal dialogues with unsung geniuses spanning various fields, Season 2 of ‘Laser Focused’ offers listeners a glimpse into the shared hurdles all engineers encounter when pioneering disruptive technologies. It equips them with the tools to construct their own roadmap for success as they pursue their ambitious ideas.”

This second season of “Laser Focused” is set to comprise 8 episodes, featuring an impressive lineup of guests. Notable figures on the roster include Gen. Ellen M. Pawlikowski, Former USAF General; Christina Korp, Space for a Better World Director; Todd Fleckenstein, Founder, CEO, and Chief Engineer of Meraki Space Systems; Jeanette Winterson, New York Times Best Selling Author, CBE, and Advisor to PhysicsX; Ellen Malloy, Manager of Manufacturing Engineering at Hermeus; and Ante Lausic, PhD, General Motors’ Lead Process Engineer.

The podcast promises to offer listeners a unique window into the world of engineering, shedding light on the challenges and triumphs that have shaped these innovators’ journeys.

Atlas Copco Group, a leader in compressors, vacuum solutions, generators, pumps, power tools and assembly systems, has begun construction of its new manufacturing facility in Talegaon, Pune. 

Atlas Copco’s new state-of-the-art air and gas compressor system factory in Talegaon will manufacture systems for the local market and also for export. It encompasses a manufacturing plant and office building spanning a total of approximate 270.000 sq. ft. and the investment planned is MINR 1400 (about MEUR 15.0). 

The new facility is planned to be completed by Q2, 2024. It will generate additional employment for over 200 people and add production capacity.

Philippe Ernens, President Oil-free Air division, commented on the announcement of the new facility, “We invest further in capacity in India to cater to the growing demand of the Indian and export markets. This expansion project is part of our strategy to remain first in mind, first in choice for our customers. It will enable us to reach new customers and markets and improve lead times to customers.”

Marcelo Kabilio, Vice President – Operations, Atlas Copco India, said, “Our passionate teams involved in designing and making these innovative products at this new factory will help support our customers’ productivity and sustainability goals.”

At the Talegaon facility, around 80% of the energy will come from solar panels and three-fourths of the water consumed will be derived from rainwater harvesting. The construction will be in line with the LEED (Leadership in Environmental Energy and Design) concept.  

Artificial Intelligence will transform the aerospace industry. According to HAL chairman and managing director, CB Ananthakrishnan Hindustan Aeronautics Ltd is deploying AI-based products and tools for aircraft component maintenance, reflecting the aerospace sector’s significant adoption of AI.

In today’s rapidly evolving technological landscape, the concept of artificial intelligence (AI) often garners both exaggerated hype and undeniable transformation. This groundbreaking technology is reshaping the way businesses operate, with machine learning emerging as the foremost AI technique. Across various industries, including aerospace, AI is being harnessed in conjunction with advanced analytics disciplines like data science and operations research to yield profound benefits.

While some challenges persist, the aerospace sector is stepping into the early phases of AI adoption, marked by the initiation of experimentation among leading companies. Although numerous single-use applications and a few end-to-end solutions have emerged, the true potential of disruptive business models driven by AI is yet to be fully realized.

The synergy between the aerospace and artificial intelligence sectors holds immense promise. AI has already begun transforming the customer experience through automation and self-service solutions, optimizing employee workflows, and enhancing air travel safety via analytical and prescriptive aircraft maintenance practices. Ananthakrishnan, Chairman and MD from HAL, emphasises the organization’s commitment to innovation and self-reliance in the aerospace sector, propelled by research, development, and cutting-edge techniques.

The aerospace industry’s swift integration of AI-based tools is significantly boosting system safety. Notably, AI-powered products and tools are making strides in aircraft component maintenance and automated carbon recognition systems. This underscores the industry’s dedication to innovation, particularly in advanced materials, manufacturing design, and techniques.

 

IIT Madras, in collaboration with a startup, is developing an indigenous software technology solution to proactively detect and prevent zero-day vulnerability attacks in 5G networks, improving network reliability.

A new indigenous software technology solution can now proactively detect and prevent zero-day vulnerability attacks in the 5G networks thereby reducing the network downtime. This can help smoothen countrywide communication as 5G networks become its lifeline in the near future.

Around ninety percent of the 5G technology is implemented into software by integrating several latest technologies (NFV, SDN, control plane/user plane segregation) which enable testing the technology easily. But attack surface area is increased multifold in this process and is impossible to manage manually. Automating the whole testing process and continuous monitoring is the only sustainable solution.

Currently majority of the run time zero-day vulnerabilities are identified post attack, thereby creating damage to the brand as well as increasing the cost of recovery.

IITM Pravartak Technologies Foundation at IIT Madras, a Technology Innovation Hub for Sensors, Networking, Actuators and Control Systems (SNACS), supported by the Department of Science and Technology (DST) under National Mission on Interdisciplinary Cyber Physical Systems (NM-ICPS), along with its incubated startup, is developing an indigenous security testing solution for 5G core network functions and Radio Access Network (RAN) software. This technology solution can automatically identify zero-day vulnerabilities in the network in advance by using techniques such as fuzzing and test oracles.

This solution has been manually tested in the 5G security lab of IITM Pravartak. Since it can help avoid the attacks in advance, it protects organisations against loss and saving the credibility of the brands.

The team used ethical hacking for finding vulnerabilities in the system. They tested the functionality issue in the network, created various attack scenarios based on topology, feature interaction, and the number of nodes involved by following the defined 5G standards of 3GPP.

The team is testing interoperability and security issues with multi-vendor products. Tests are conducted at the network packet level, the binary level, the code level and also using the code vulnerability scanners. A combination of all these methods will help reducing zero-day attacks by pre-emption mechanism.

Reducing zero-day vulnerabilities will reduce attack surface area, which in turn will reduce the need to pay ransom and also decrease network downtime of 5G networks which are crucial for communication.

Schwing Stetter India partners with SRM Easwari Engineering College to offer a one-year on-the-job training program, bridging the gap between academia and industry for engineering students.

Schwing Stetter India, one of the country’s leading construction and concreting equipment manufacturer, has announced its partnership with SRM Easwari Engineering College, Chennai to provide a comprehensive one-year on-the-job training program for engineering students specializing in Civil, Mechanical, Electrical and Electronics, Electronics and Communication, Robotics and Automation, and Automobile Engineering.

The initiative’s goal is to bridge the gap between academia and the industry by giving students practical knowledge and skills. And to ensure that their program is relevant with current industry standards and practises, Schwing Stetter India has customised the training course to comply with the guidelines of the University Grants Commission (UGC).

As part of the program, selected students will have the opportunity to work closely with Schwing Stetter India’s experienced professionals and gain insights into the manufacturing sector. Through hands-on experience and exposure to real projects, students can work on their problem-solving abilities, technical proficiency, and engineering skill development.

Speaking about the importance of such industry academia initiatives, V.G. Sakthikumar, Chairman and Managing Director of Schwing Stetter India said, “Our company’s vision is to develop young talent and create a strong connection between academic knowledge and practical application. This collaboration aims to give students the tools they need to succeed in the workplace, spur innovation and make significant contributions to the manufacturing industry.”

Furthermore, Schwing Stetter India extends a collective medical insurance scheme to all enrolled students. With a steadfast dedication to the interns’ welfare, the company will secure them under this policy, affording coverage worth Rs 1 lakh during their training period.

Tezmaksan, a European manufacturer of robotics and automation, will launch three new iterations of its innovative CubeBOX system at EMO Hannover 2023. Held on 18 to 24 September, EMO is among the world’s largest fairs for metalworking and manufacturing. Tezmaksan Robotics will demonstrate its new automation systems in hall 17 stand B06. 

CubeBOX is a revolutionary series of automation solutions that enable operator-free production in machine tending. Developed by Tezmaksan, the systems integrate with any control unit and any robot of the user’s choice — regardless of manufacturer or communication protocol and can support the automated loading and unloading of CNC machines.

Among the launches at EMO is the CubeBOX Pallet Pool, also referred to as Pallet Tower and Pallet Changer. The system is used for automation of CNC machining centres with limited floor space and can manage up to 24 pallets and 16 tools with just one unit. Pallets are arranged in a compact circle in front of the machine, using a 6-axis robot to load and unload into the system. The equipment significantly reduces reliance on operators for loading and unloading and can enable up to 24-hour operator free operation.

Other demonstrations include the CubeBOX RT Stacker (RT-S). The RT-S is suitable for lathes and vertical machining centres. The system uses two pallets for part loading and can tend one or two CNC machines. A key advantage of this model is the ability to stack two pallets on top of each other, enabling higher throughput without an increased factory footprint. 

Tezmaksan will also exhibit the CubeBOX Space Cabinet. This model boasts three drawers for holding product which is unloaded using a 6-axis robot. Using this system, an operator does not have to regularly restock the system. When restocking is necessary, the CubeBOX Space Cabinet’s ergonomic design allows drawers to be rolled into a reachable position for easy parts supply.

Hakan Aydogdu, general manager at Tezmaksan. explained, “Automating the loading and unloading of CNC machines can have significant financial, efficiency and productivity rewards. CNC machining requires high precision and accuracy and improper loading and unloading can result in misalignment or damage to the workpiece — that is not to mention the time dedication required for physically handling parts. Another consideration is operator skill and availability. CNC machines are designed for continuous operation, so minimising downtime by reducing operator reliance is crucial.”

Impressively, the CubeBOX can increase night shift productivity by up to 50 per cent, enabling an average return on investment (ROI) of just eight months. 

All CubeBOX systems lean on RoboCAM — smart automation software from Tezmaksan. RoboCAM allows operators to integrate CubeBOX with any accompanying robot with no prior robot programming knowledge required. An operator simply uploads product drawings and RoboCAM translates these into a language the robot can understand and action. This software will be demonstrated alongside all three CubeBOX launches at EMO 2023. 

“RoboCAM and CubeBOX are essential technologies for the flexible and serial production system model — an engineering style that Tezmaksan has pioneered for several decades,” added Aydogdu. 

Tezmaksan’s presence at EMO Hannover 2023 will offer attendees firsthand demonstrations of the three new CubeBOX systems. Visitors will also have the opportunity to discuss their requirements with the Tezmaksan engineering team, who can provide consultation on automated technologies for machining. 

For more information, visit the Tezmaksan Robotics website.

The objective behind ABB India securing a contract with Reliance Life Sciences to implement automation and control solutions in their biosimilars and plasma proteins manufacturing plants in Nashik, Maharashtra is to achieve operational excellence throughout the manufacturing processes.

ABB India has secured a significant automation contract from Reliance Life Sciences (RLS) to automate their newly established manufacturing plants in Nashik, Maharashtra. RLS’s sprawling 160-acre facility in Nashik will be home to manufacturing units producing plasma proteins, biopharmaceuticals, oncology pharmaceuticals, and vaccines.

Managing large-scale biotechnology production presents intricate challenges in terms of processes and automation. These processes strictly adhere to regulatory guidelines to ensure the quality of products. ABB’s System 800xA® solution reduces manufacturing errors and ensures high-quality yields. This solution seamlessly interfaces with different skid systems and is extensively employed for smooth operator interaction, batch control, and production information on the factory floor.

1. Balaji, Senior Vice President and Head of Energy Industries at ABB India highlighted ABB’s strong positioning in the pharma and life sciences sector, emphasising the potential for growth and innovation. As India solidifies its position as a biopharmaceutical manufacturing hub, ABB India is well-prepared to capitalise on the automation-driven industrial revolution in these sectors, pivotal for maintaining large-scale production with assured quality.

K.V. Subramaniam, President of Reliance Life Sciences, noted the company’s tradition of leveraging automation technologies for quality and productivity enhancement in its manufacturing processes. The collaboration with ABB represents continuity in this approach and advancement in virtualisation and process control.

ABB’s System 800xA solution
System 800xA will be installed in a virtualised environment for RLS. This move offers cost and operational benefits by simplifying server management and reducing the IT footprint, subsequently lowering operational costs. ABB’s multichannel remote I/O solutions will facilitate efficient data communication, reduce wiring complexity, optimise hardware space utilisation in the plant, and expedite project execution. Given the pharmaceutical nature of the manufacturing unit, the DCS (Distributed Control System) will adhere to US FDA 21 CFR Part 11 standards.

The latest Windows Server 2022 platform will provide the DCS, ensuring extended lifecycle support and top-notch software management. This approach avoids plant shutdowns for software upgrades, decreasing overall costs associated with downtime, software/hardware updates, and related services. The integration offered by System 800xA brings together various plant components, eliminating the need for multiple PLCs. This integration guarantees a unified audit trail, integrated data reports, and streamlined operations, reducing maintenance requirements, training needs, and inventory complexities. Additionally, it simplifies third-party audits. Alongside the DCS, RLS will adopt ABB’s modular remote I/O solution, which offers flexibility and a plug-and-play concept for automation. This approach enables quicker commissioning and process implementation, with the added benefit of scalability for future capacity expansion.

As Reliance Life Sciences expands its manufacturing capabilities, they intend to produce high-quality biosimilars at an affordable cost. With the largest number of biosimilars in India and a global development pipeline, the company’s expansion aligns with its goal to become a major player in the biopharmaceutical industry.

ABB has a track record of delivering advanced DCS solutions to prominent pharma companies in India and has been recognised as the world’s leading DCS provider for 23 consecutive years, according to the ARC Advisory Group’s 2021 report. 

For more details, visit: go.abb/process automation 

Cummins India drives BS-VI emission norm awareness with innovative training vans, empowering technicians, drivers, and stakeholders across the automotive industry.

Cummins India will flag-off of the BSVI OBD II training vans. The vans will offer hands-on education and understanding of BSVI OBD II technology to mechanics, technicians, vehicle body fabricators, truck drivers, and customers across OEM dealerships and authorized workshops. The vans were flagged off from the Cummins India Office campus by Mr. Rajendra Petkar, President and Chief Technology Officer, Tata Motors, Ms. Anjali Pandey, Chief Operating Officer, Cummins India, and Mr. Nitin Jirafe, Vice President, Engine Business, Cummins India along with leadership teams of Tata Motors and Cummins.

The training vans are equipped with Cummins BSVI engines (B5.6 and B6.7), cut sections of engine parts, a selective catalytic reduction (SCR) system, and a single-module after-treatment system. This provides an immersive experience for participants, who can see and touch the actual engines and learn about their components and operation. The vans also have LCD TVs that play training videos and information on Cummins BS-VI engines in rich audio-visual format.

In addition to  serving as mobile classrooms, the vans also showcase the benefits of Cummins engines, after-treatment systems, and an extensive range of offerings from Cummins for the on-highway aftermarket, such as Genuine Cummins parts, Saathi mobile app for truck drivers, Components Care Centers (CCC), and Vishwasji (a visual rendition of an expert embodying trust, experience, innovation, and expertise that resides in each one of the aftermarket sales and service members of Cummins India)

Speaking at the launch Nitin Jirafe, Vice President, Engine Business, Cummins India said, “At Cummins, it is our constant endeavor to create and deliver world-class customer experiences that demonstrate our vision of innovating for our customers to power their success. Currently, there are more than 2.4 Lakh Cummins BSVI-powered vehicles plying on Indian roads. These BSVI OBD II emission-compliant engines further reinforce our commitment toward powering a cleaner India.”

Mohan Ramachandran, Commercial Director, Engine Business and Aftermarket, Cummins India further added, “The training vans offer multiple benefits – educating the truck drivers about the engine, which helps improve fuel efficiency through better drivability; reducing the carbon footprint of the CVs in use; and last- mile reach, which helps deepen our connect with the stakeholders.”

With the BSVI OBD II Training Vans, Cummins India continues to empower individuals and strengthen the automotive ecosystem by equipping them with the knowledge and expertise needed to navigate the cutting-edge BS-VI technology era.

Since the launch of the first mobile training fleet in November 2019, the vans have successfully conducted cumulatively over 1300 sessions in 1640 cities, and have trained more than 20,000 technicians, vehicle body fabricators, and drivers, contributing to their knowledge and skill enhancement.

Use heater control panels with thyristor power regulators to achieve precise temperature control for your oven, furnace, or air handling unit.

Libratherm electrical control panel systems use PID controllers and thyristor/SCR power controllers to regulate the power supplied to the heating elements. Temperature sensors provide data to the PID controllers, which signal the thyristor power regulator to adjust the power output accordingly. With continuous temperature monitoring in a closed-loop control system, Libratherm control panels include all the necessary components, such as safety switch gears, busbars and power cabling, thermal regulation, and an enclosure. This comprehensive solution offers customers a ready-to-use system for controlling their heating equipment.

Benefits of Power Control Systems Using Thyristors
The Thyristor Power Controller is a reliable and precise tool for managing the process in proportion to the control signal. It offers a seamless approach to regulating the power supplied to the load. Unlike Contactors, thyristors do not have any mechanical movement, eliminating the risk of sparking, arcing, and carbon buildup. They gradually supply power to the heating load, preventing electrical surges and transients and ultimately extending the lifespan of the heating components. Using thyristor power controllers can enhance the energy efficiency of heaters by reducing energy losses as they can be turned on and off quickly, which reduces the time the heater consumes power. They are ideal for industrial applications where dust, dirt, or moisture may pose a risk. Libratherm has a range of Thyristor Power Controllers that can handle loads from 10A to 1000A. The Libratherm thyristor power controllers come equipped with a current limit and overload trip function that safeguards the valuable heating elements against damage caused by overload. This feature also eliminates the requirement for physical fuses that the user must manually replace in case of an overload trip. 

Applications
Thyristor power controllers find their use in various applications where there is a need for accurate and precise control of heaters. These applications include: 

• Aluminium Melting Furnaces 
• Holding Furnaces 
• Air Handling Units 
• Dehumidifiers 
• Boilers Hot Air Generators and Hot Air Dryers 
• Very high-temperature furnaces built using Silicon Carbide/MoSi2 heating elements
• Microwave dryers 
• Multi-zone Drying and Curing Ovens 
• Heat Transfer Printing Machines 
• Food Grains, Paper and Printing Drying Ovens made using Quartz tube Medium wave IR and Ceramic coated IR heaters. 
• Pet bottles Pre Forms preheating tunnel ovens made using IR heaters 
• Plastic Injection moulding requiring multi-zone heating for manifold moulds 
• Plastic Pipes and Sheets extrusion 
• Metal sheets welding systems

For more information visit www.libratherm.com

 

In this article, Ravichandran Duraisamy, Senior Product Manager, Messer Cutting Systems, talks about modern advancements such as process automation, digitalisation, and robotics in the cutting process. This shift has been noticeable and has given rise to numerous technology-based startups throughout India that cater to the growing demand for innovative solutions in these areas.

As a leading player in the thermal cutting industry, we have observed significant growth in the Indian industrial sector, driven by consistent demand conditions. Despite facing challenges in the global supply chain, the Index of Industrial Production (IIP) has shown remarkable progress, increasing from 2.8 percent in 2015-16 to an impressive 21.2 percent in 2021-22. This growth has been substantial enough to elevate the Indian economy from the 10th to the 5th largest in the world over the past nine years, as the Press Information Bureau (PIB) reported.

Looking forward, the recent 2023-24 union budget presents promising opportunities for further development in various industrial sectors. Key areas of focus include Infrastructure and Investment through initiatives like Project Saptarishi and substantial investments in the Railways, with a capital outlay of 2.40 lakh crore. These measures are expected to create an environment conducive to industrial growth and foster economic advancement in the country. We foresee a lot of opportunities in Infrastructure development and related sectors.

Evolution of Indian Industry in the last decade
The industry has transformed, moving away from traditional general engineering methods towards embracing modern advancements such as process automation, digitalisation, and robotics. This shift has been noticeable and has given rise to numerous technology-based startups throughout India that cater to the growing demand for innovative solutions in these areas.

Challenges in the current scenario
One of the major challenges across industries is the need for a more skilled workforce. In the manufacturing sector, the labour cost of skilled workers is approaching the levels seen in the IT industry. Adopting digitalisation and automation is becoming increasingly crucial to bridge this gap and enhance productivity.

Recognising the importance of technological advancements in the Indian manufacturing sector, the government has taken proactive steps to promote Industry 4.0. Initiatives like SAMARTH (Smart Advanced Manufacturing and Rapid Transformation Hubs) and UDYOG Bharath 4.0 aim to encourage the integration of cutting-edge technological solutions to address the workforce and productivity challenges in the industry. Moreover, the re-emergence of COVID-19 may create supply chain disruptions.

The future of thermal cutting
Laser cutting has become the favoured cutting technology in the industry, primarily due to its outstanding performance and cost-effectiveness. Incorporating additional processes, such as beveling and drilling with plasma, has further streamlined operations, reducing the need for multiple post-cutting tasks.

In response to the demand for increased efficiency and cost savings, industries have embraced automation to enhance productivity, optimise material movement, and manage inventory more effectively. Automation is proving to be a valuable solution in light of the scarcity of skilled workforce.

Just as the future of mobile phones in India began slowly but eventually expanded to make us one of the largest consumers globally, automation is expected to follow a similar trajectory across all sectors of Indian industries. Process automation and digitalisation will likely become widespread due to the imperative need to address the challenges of the lack of skilled labour.

Partner of choice
With a rich legacy of 125 years, we are trailblazers in the thermal cutting industry, catering to global customer needs. Our extensive collective experience sets us apart, as does our in-depth application knowledge and capacity to deliver solutions to even the most intricate customer challenges. Our innovative product lineup incorporates state-of-the-art technology backed by a robust after-sales support infrastructure and personalised service assistance.

As a partner of choice, we take pride in offering products that utilise all three energy sources – Oxyfuel, Plasma, and Laser – ensuring we cater to diverse customer categories. Our comprehensive solutions also encompass Material handling and automation, enabling us to effectively serve customers across Pan India.

Our product range is designed to be modular and cater to various customer requirements. We have Bevel Units specifically designed for weld edge preparation among our offerings. Additionally, we offer OmniWin, a cutting-edge Professional Nesting tool to optimise cutting processes efficiently.

Additionally, we offer a range of automation products, including-

• Machine Insight (MI) for machine monitoring
• Production Data Capture (PDC) for live data
• ERP Connect to integrate with customers’ ERP
• Auto Plate management
• Integrated machine with software solutions.

These automation products complement our offerings and enhance our customers’ efficiency and productivity.

As a customer-oriented solution provider, Messer India boasts a robust and well-established continuous product development process, enabling us to effectively meet all the diverse requirements of the thermal cutting industry.

 

 

VE Commercial Vehicles (VECV) and IIT Indore join forces through a five-year MoU, fostering scientific exchange, skill development, and educational opportunities for VECV employees, promoting research collaboration and innovation.

VE Commercial Vehicles (VECV) signed a Memorandum of Understanding (MoU) with IIT Indore (IITI) for a period of five years. This partnership will facilitate the exchange of scientific information between VECV and IIT Indore and shall open channels for the development of competencies required for the rapidly modernizing auto and its future talent. This partnership will also facilitate VECV employees to acquire MTech, MS(R), and Ph.D. degrees from IIT Indore.

The MoU was signed by Prof. Suhas S. Joshi, Director, IIT Indore and Mr. Rajinder Singh Sachdeva, Chief Operating Officer, VE Commercial Vehicles. 

Commenting on the partnership, Mr. Rajinder Singh Sachdeva, Chief Operating Officer, VE Commercial Vehicles, said, “This is a VECV-sponsored program for its employees. We will do a stringent internal selection process and hope to have an exchange of about 100 students and employees, in a time frame of five years. This MoU will also enhance collaboration in research and academics in the areas of mutual interest.”

As part of the MTech program, VECV employees will be required to pursue online coursework in the first year. Project work in the second year will be conducted either at VECV’s Pithampur and Bhopal Plants or at IIT Indore under the guidance of the assigned thesis supervisor(s) of IIT Indore. 

Prof. Joshi, said, “This cooperation will cover joint research, scientific mobility, exchange of scientific and technical information, exploitation of research results and transfer of technology. It will also help in the training of VECV employees, internship of students from IITI, and facilitation of workshops, research and consultancy projects.”

Such partnerships between corporates and academic institutions have the potential to produce cutting-edge technology that is affordable and can support the Make in India effort. They also have the potential of making Indore, one of India’s leading centres of research and development.

Headquartered in Bengaluru, FANUC India has been supporting the manufacturing industries in the Indian subcontinent for more than 30 years.

FANUC India provides industrial automation solutions – ranging from CNC controllers, Laser CNC, Robots, Vertical Machining Centres, Electric Injection Moulding machines & CNC Wire EDM. Coupled with complete integration of factory automation systems – lifetime service support forms a one-stop solution for its three core businesses “FA – ROBOT – ROBOMACHINE”. A global leader, FANUC has more than 260 offices in 107 countries.

Since its founding 31 years ago, FANUC India has made great efforts in collaboration with the manufacturing sector to develop the industries in India. During this time, it has established more than 20 branches around India and has provided technical support and maintenance services to customers in each region.

“FANUC has been supporting India for more than three decades with made-for-India Factory Automation products. This Chennai facility is a reaffirmation of FANUC’s endeavour to serve the Indian manufacturing sector with a focus on Make-in-India and enabling the emerging sectors to be globally competitive. Technologies are advancing towards convergence and FANUC is at the forefront of digitalisation, among other exciting developments,” Dr. Inaba said.

Conforming to the spirit of “Service First” FANUC provides lifetime maintenance for its products for as long as they are used by customers, through our 21 service locations supporting five countries in the Indian subcontinent.

Being the fastest growing economy in the world, India is a very important market for every business house. The well-educated, skilled, and English-speaking young population makes India an even more attractive place for business. In that, the State of Tamil Nadu plays a very crucial role.

“Famous for its tradition, culture, and hospitality, Chennai city is very dear and close to our hearts. In fact, the first Branch Office, after establishing our headquarters in Bangalore in 1993, was in Chennai in 1994. Since then, we have been serving the region by enhancing our services day by day,” Dr. Inaba added.

In addition to the advantages of its geographical location with a port and excellent infrastructure, Chennai has many talented engineers and experts with high skills and has become a major industrial city in this country. This has attracted many big automotive manufacturers, which have set up production facilities here. 

“There are approximately 5,000 companies in Chennai that are customers of FANUC India. More than 50,000 FANUC CNCs, ROBOTs, and ROBOMACHINEs are in operation in these factories. Exceeding our expectations, this region developed extremely rapidly. In addition to the automotive industry, other industries such as the smartphone, household appliances, FMCG, and the plastics industry expanded into Chennai, increasing the city’s importance even more,” said, Yuki Kita, FANUC India.

“To reach out and serve the industries even better than in the past, we decided to establish our own facility in Chennai and purchased this piece of 4 acre-land in Sriperumbudur, and built a 67,000 sq. ft. facility, equipped with all essential infrastructure and resources,” he informed.

The new building is designed to be earth friendly. Material that is optimal for thermal and acoustic insulation has been used effectively, as well as exposed concrete and exposed walls with compressed stabilized earth blocks. Such a structure offers a comfortable office environment that suits the high and humid climate of Chennai while being ecological.

FANUC is committed to supporting industries at every step in factory automation, technology advancement, and turnkey solutions. As a matter of policy, lifetime maintenance support is assured for FANUC Products.

The energetic team of 33 young talented engineers is dedicated to serving the Chennai region and is well supported by FANUC India, Bengaluru, and FANUC, headquartered in Japan.

ELGi North America partners with non-profit Digi-Bridge to empower students in Charlotte with hands-on STEAM experiences, fostering growth and bridging the gap between education and real-world applications.

ELGi North America (ELGi), a subsidiary of ELGi Equipments Limited, air compressor manufacturers, has partnered with Digi-Bridge. A non-profit organization, Digi-Bridge provides students with access to hands-on, technology-based (STEAM) science, technology, engineering, arts, and math experiences, ensuring they are well-equipped with the skills to succeed in a rapidly evolving world. As part of the partnership, ELGi supports the Southwest Charlotte STEM Academy with its after-school STEAM program. The partnership kicked off with ELGi’s employees undertaking a group activity to disassemble and organize LEGO robotic kits for the students.

Piper Barnes, Development Director at Digi-Bridge said, “We’re excited to join forces with ELGi, an engineering-driven company that shares our values and vision for a future where all children have equal access to educational opportunities. Together, we look forward to expanding our efforts and impacting more children.”

“At ELGi, we believe in fostering development and growth via special focus community outreach programs that engender a transformative effect on those that truly need it. Our partnership with Digi-Bridge will provide children in the Charlotte area with fascinating and enjoyable experiences to stimulate their intellectual curiosity in STEAM subjects. STEAM education is proven to create critical thinkers who will form the next generation of innovators.” said Anvar Varadaraj, Executive Director Elgi Equipments Ltd.

Going forward, ELGi plans to expand its collaboration with Digi-Bridge by offering mentorship opportunities to students and organizing hands-on workshops. These initiatives aim to bridge the gap between students’ academic knowledge and real-world scenarios. Furthermore, ELGi plans to host field trips to its Charlotte, North America office, enabling students to experience a modern workplace and interact with industry professionals.

Launched in 2014, Digi-Bridge has provided technology-based, hands-on STEAM experiences to more than 17,000 students. The organization accomplishes this through STEAM and robotic programming with various schools and community partners.

CUMI and ideaForge Technology are collaborating to develop innovative nanomaterial reinforced structures to make drones lighter, stronger, smaller, and more durable.

Carborundum Universal Limited (CUMI), a pioneering organisation in the field of material sciences and part of the 120-year-old Murugappa Group collaborated with ideaForge Technology, India’s leading drone maker, to jointly develop cutting-edge nanomaterial reinforced composite parts for drones.

Nanomaterial-reinforced composite materials (such as graphene-reinforced polymers) hold the promise of transforming structural parts for aerospace applications. They offer several improvements in physical properties over standard composite materials which can include higher mechanical strength, greater toughness and stiffness, better electrical and thermal conductivity, superior fire retardancy and higher barrier to moisture and gases. Nanocomposites also offer unique design possibilities, which offer immense potential in creating materials with desired properties for specific applications. The use of the appropriate nanomaterials can help build drones that are smaller, lighter, stronger, and more durable, among others.

Speaking about the collaboration with CUMI, Sunil Jha, Sr Director of Engineering, ideaForge Technology said, “The use of nanomaterial reinforced composites in drones offers several exciting possibilities such as higher specific modulus or strength and is likely to shape the future of airframe and related structural components of drones. We are excited to partner with CUMI, which has done some pioneering and innovative work in the field of material science over the years.”

Subbu Venkatachalam, Head of Marketing, Carborundum Universal Limited, said, “ideaForge has done pioneering work in advancing drone technologies and building its position as the leader in the Indian unmanned aerial vehicles market. I am confident that with the deep expertise we have built in the field of materials, this partnership will bring some significant synergies and shape the next generation of drone technologies. We look forward to an exciting and rewarding collaboration that will significantly strengthen the ‘Make in India’ movement and chart new opportunities.”

CUMI’s Composites Manufacturing Division has over five decades of experience in the design, manufacturing, and testing of composites. CUMI’s composites facility develops cutting-edge composite technology for unmanned aerial vehicles (UAVs) including CFRP tubes, panels, landing gears, and customised composite structural parts for drones. Its dedicated dust-proof facility to manufacture CFRP parts for UAVs has process capabilities such as vacuum infusion and vacuum bagging, Resin Transfer Moulding (RTM), Pultrusion, and Filament Winding, among others.

MOTOTECH23 will be held at Hotel Sheraton Grand on September 22, 2023, in Pune, Maharashtra.

With an impressive compound annual growth rate (CAGR) of 11.30% projected from 2022 to 2027, the Indian Automotive Industry is poised to scale new heights, targeting a production milestone of 70 lakh units by 2027. To realise this ambitious goal, the automotive sector is embracing a spectrum of advanced technologies. These encompass Digital Twins, 3D Printing, Automotive Lightweighting, Connected Cars, Software Designed Vehicles (SDVs), Alternative Fuels, Enhanced Safety Mobility, Resilient Design & Simulation Techniques, and Innovative Manufacturing Processes.

MOTOTECH 2023, marking its inaugural edition, emerges as the pioneering conference that comprehensively explores the facets shaping the Indian Automotive Manufacturing landscape. Esteemed industry experts will convene at this one-day event to deliberate on cutting-edge technology trends, fostering discussions that delve deep into the future landscape of automotive technology.

A diverse array of participants from across the automotive spectrum, including Automotive Original Equipment Manufacturers (OEMs), Auto Component Producers, Machinery and Tool Manufacturers, Die & Mould Creators, and Manufacturers of Software Services for Production, will converge at the conference. Esteemed figures within the industry, including Managing Directors, Chief Executive Officers, Chief Technical Officers, Technical Directors, Vice Presidents, General Managers of Manufacturing, Plant Leaders, Production Heads, Heads of Design and Research & Development, and Quality Control Heads, will grace the event with their presence, offering invaluable insights drawn from their wealth of experience.

Conference Highlights
The conference will delve into a diverse range of automotive industry topics, reflecting advancements reshaping the sector. The conference will cover digitalisation, Alternative Fuels, Role of AI in Autonomous Vehicles, Steel – A Gamechanger in Automotive Light weighting, Addressing Challenges of EV – Battery Swapping, Battery Prices, RE based charging, Connected Cars, HMI in Automotive Industry, Machining Trends in Automotive Manufacturing (CNC, Grinding, Coolants, Tooling, Cutting etc.), SDV’s (Software Designed Vehicles), AGVs & Robots.

The Distinguished Chairman and Guest of Honour
The esteemed position of Chairman will be held by Nasir Deshmukh, who serves as the Sr. Vice President of Manufacturing Operations and is the Plant Head at M&M’s Chakan Plant in Pune. Adding to the event’s prestige, Mr. Uday Narang, the Chairman of Anglian Omega Group & Omega Seiki Mobility, will be the Guest of Honour, bestowing the conference with his esteemed presence.

Confirmed Speakers
Among the eminent speakers gracing the event are notable personalities like K. Arunagiri (Head Business Development eMobility – Motor Vehicle Industry, Atlas Copco (India) Ltd.), Dr. Ravindra Utgikar (Vice President – Corporate Strategy, Praj Industries Ltd.), Shikhar Gupta (Director, Energy & Mobility, PwC AC), Rajesh R Kumathekar (President, Advantek Fuel Systems), Neelam Pathak (Veteran in Automotive Industry), Satish Patil (Deputy General Manager, Fiat India Automobiles Pvt. Ltd.), E. Rajiv (Executive Director – IACE, International Automotive Centre of Excellence), Sachin Sanghi (Principal Architect – Manufacturing, Google Cloud), Ajay Kavade (Senior General Manager, ŠKODA AUTO Volkswagen India Private Limited), Shatyabrata Das (Sr. General Manager, IAC – International Automotive Components), Ravindra Gugale (Sr. GM Purchase, Tata Autocomp Systems Ltd), Naveeth Menon (Vice President, Sales & Marketing, BAXY Mobility), Shirish Kulkarni (Founder & MD – STROTA ConsulTech Pvt. Ltd.), Akshay Sasikumar ( CEO – 82Volt Technology), Durgesh Guptaa (VP-Sales – Bgauss), Shashank Sathe (CTO- Chief Technology Officer – Magenta Mobility), Anuj Budhiraja (Vice President – Phillips Additive – India Phillips Machine Tools), Akshay Sasikumar (CEO – 82Volt Technology) and Pranjal Mathur (Research Manager – DataM Intelligence 4Market Research LLP).

Event Partners
The MOTOTECH23 event is made possible with the collaboration of various partners. Notably, Additive Manufacturing – Markforged Philips – Machine Tools holds the position of Special Partner, while Atlas Copco takes on the role of eMobility Partner. HUSKY and STOROpack are recognised as Associate Partners, the Academic Partner is IACE (International Automobile Centre of Excellence) and DataM Intelligence would be Market Research Partner.

Engaging Opportunities
MOTOTECH 2023 offers sponsorships and speaking opportunities for interested parties. For sponsorship, one can contact +91 88260.68345 or email sudhanshu@itmgroupmedia.com. Contact Sagar Tamhane at +91 98206.92293 to explore speaking opportunities or email sagar@itmgroupmedia.com. For delegate participation, contact Radha Poptani at +91 98209.51287 or email radha@itmgroupmedia.com.

Be a Part of the Future
The conference promises to be a gateway to shaping the future of the Automotive Industry in India. All interested parties are invited to join MOTOTECH 2023 and be part of the influential conversations that will pave the way for automotive technology advancements in the country.

For more details, visit the official website: www.mototechindia.in

The Society of Indian Automobile Manufacturers (SIAM) organized a global conference on World Biofuels Day 2023, focusing on sustainable mobility and biofuel integration in the automotive industry. The event featured experts discussing eco-friendly practices, policy initiatives, and technological innovations for a greener future.

In a bid to champion eco-friendly and sustainable transportation, the Society of Indian Automobile Manufacturers (SIAM) hosted a major global conference on “Paving the Path to a Greener Future: Commemorating World Biofuels Day 2023”. The event aimed to exchange insights and expertise on steering the automotive industry towards sustainability using biofuels. The conference covered a wide array of biofuel-related topics, including production, utilization, India’s biofuel policies, worldwide initiatives, and cutting-edge technologies. Experts and key players in the industry came together to discuss and brainstorm strategies for integrating biofuels into the automotive sector, driving environmentally-conscious practices forward.

Shri Ashwini Kumar Choubey, the Hon’ble Minister of State, Ministry of Environment, Forests, and Climate Change, Govt. of India, graced the conference as Chief Guest and addressed the gathering,“Our government has emphasized on preserving our environment while meeting the needs of our sustainable lifestyle. We have encouraged the production of different non-fossil fuels and added a huge amount of renewable energy. Biofuel can play a key role in India’s transition to clean energy and facilitate net-zero goals. The automotive industry has been making efforts to bring down emissions, and biofuel and ethanol blending will augment this action.”

Addressing the inaugural session, themed “Sustainable future of Automotive industry with Biofuels”, Mr. Sunil Kumar, Joint secretary (Refinery)-Ministry of Petroleum & Natural Gas, said, “India has enormous potential to produce biofuels and achieve self-reliance with the use sugarcane and maize. The automotive industry is contributing immensely to emissions reduction with a focus on implementing BS-VI. The government is dedicated to offering all assistance through supportive policies and programmes.”

Giving the sugar mills perspective, Mr. Aditya Jhunjhunwala, President of the Indian Sugar Mills Association, said, “Climate change is a significant challenge that necessitates to think over greener, more sustainable solutions. Biofuel has emerged as one of the most viable energy options, which calls for collective efforts from all the major stakeholders.”

Mr. Abhay Bakre, Director General of the Bureau of Energy Efficiency, said, “It is crucial to focus on reducing costs to encourage consumers to use biofuels, promoting technology advancement to make production cheaper, and improving the supply chain to ensure smooth transportation and enhance consumer comfort. The transportation sector is making great endeavours to reduce emissions and its move towards biofuel promotion is commendable. We, at BEE, are working to create a robust carbon market and hope that the industry will reap the benefits.”

Guest of Honour, Mr. Jonathan M. Heimer, Minister Counselor for Commercial Affairs at the US Commercial Service, US Embassy, New Delhi, promised his support of biofuel adoption in India by saying, “India’s efforts and initiatives show its unwavering commitment to creating a sustainable world. The India-US partnership will benefit India with biofuel expertise and technologies and help it reduce reliance on biofuel imports.”

The session included thematic presentations from Mr. Ashim Sharma, Senior Partner, Nomura Research India, on “Driving Biofuel Economy in India”. Mr. Rajesh Menon, Director General, SIAM, and Mr. Prashant K Banerjee, Executive Director, SIAM, shared their perspectives and emphasized on the implementing imperatives of sustainability achieving a sustainable future for the automotive industry with biofuels.

The first Plenary Session, titled “Sustainable Feedstocks for Biofuel Production & Automotive Industry Perspectives”, was chaired and moderated by Dr. SSV Ramakumar, Former Director, IOC R&D. The session included a panel discussion on “Exploring Feedstock options for Biofuel Production & Auto Industry Collaboration for Biofuel Integration“, which featured Dr. Sangeeta Kasture, Scientist F, Department of Biotechnology, Ministry of Science and Technology, Mr. Rajneesh Agarwal, Secretary General, UP Distillers Association, and Mr Subhash Kumar, Former Chairman & Managing Director & Director Finance, ONGC, India, Member Energy Transition Advisory Committee, MOPNG.

Mr. Yash Mankame Executive Vice President -Bioenergy, Praj Industries presented his views about Successful Biofuel Projects in India and the Lessons Learned. Prof. Y.B. Ramakrishna, Member, Working Group on Biofuels, Ministry of Petroleum & Natural Gas gave his views on Emerging Trends on Biofuels, further potentials and Policy enablers, during the session.

2nd Plenary Session, titled “Biofuel Polices and Initiatives in India”, was chaired and moderated by Mr. C.V. Raman, CTO, Maruti Suzuki India Ltd. The session included a panel discussion on “Unlocking the Potential of Biofuels in India: Opportunities & Roadblocks”.

Dr. Shantanu Gupta, Executive Director, Alternative Energy and Sustainable Development, Indian Oil Corporation Limited, expressed his views and highlighted that, “Biofuel is one of the best options we have today, which demands augmented actions. The government has taken a futuristic step with the Gobardhan scheme that focuses on turning waste into wealth. Within the next two years, there will be more than 500 “waste to wealth” facilities.”

Dr. Reece Cannady, Director for South Asia, US Grain Council expressed his views about “Challenges vis-à-vis strategies for ethanol blending as a sustainable vehicle fuel for achieving net zero mobility- An Indo-US Perspective”, and further added, “Apart from maize, there are many options from which biofuels can be produced. India has immense potential to produce biofuel and meet a majority of its energy needs indigenously.”

Dr. Reji Mathai, Director, ARAI presented his views on “Regulatory Framework, Testing and Standardization for Biofuels in transportation”, and Mr. Ravi Gupta, Executive Director, Shree Renuka Sugars Ltd. presented about “Biofuels in Transportation 2025: Policy, Commercial Opportunities & Challenges” during the session.

3rd Plenary Session, titled “Global Innovation in Biofuel Technology”, was chaired by Mr. Harjeet Singh, Senior Executive Advisor, Hero Motocorp Ltd, and moderated by Ms. Nidhi Verma, Team Leader (Energy), Thomson Reuters. The session further included a panel discussion, which included domain experts like Dr. Preeti Jain, Global Director, Lanza Tech, Mr. Neelkanth Marathe, Executive Director, Emission Control Manufacturers Association, Mr. Vedang Pitte, Promoter, Harinagar Sugar Mills, and Sqn Ldr Ankur Naik, Punjab Renewable Energy Systems Pvt. Ltd.

Concluding the day, Mr. Prashant K Banerjee, Executive Director, SIAM, said, “India is rising by the day and strives to accomplish the aspirations of every citizen during the ongoing “Kartavya Kaal”. The World Biofuels Day serves as a reminder that we have a huge untapped energy resource that we should capitalize on. SIAM is unflinchingly committed to promoting sustainability in the automotive sector.”

SIAM with its members has been engaging with governments, corporates, and stakeholders in an effort to address sustainability issues, aligning with SIAM’s objective of Building the Nation Responsibly.

Revolutionizing work dynamics, collaborative robots enhance productivity by seamlessly integrating humans and machines. Asia-Pacific dominates the market, while key players like Universal Robots and ABB drive innovation.

Collaborative robots, or cobots, are a unique type of robotics designed to seamlessly interact with humans in shared workspaces. They enable a harmonious collaboration between robots and humans on production lines, eliminating the need for restrictive barriers or enclosures. This innovation maximizes both the efficiency of robots and the intelligence of humans, effectively combining their strengths. These machines strike a balance between ensuring safety and fulfilling the need for adaptable productivity.

Collaborative Robot Market Share

Asia-Pacific is the largest market with about 54% market share. Europe is follower, accounting for about 29% market share.

The key players are Universal Robots, ABB, Rethink Robotics, Kawasaki, KUKA, FANUC etc. Top 3 companies occupied about 74% market share.

The research report has incorporated the analysis of different factors that augment the market’s growth. It constitutes trends, restraints, and drivers that transform the market in either a positive or negative manner. This section also provides the scope of different segments and applications that can potentially influence the market in the future. The detailed information is based on current trends and historic milestones. This section also provides an analysis of the volume of production about the global market and about each type from 2016 to 2027. This section mentions the volume of production by region from 2016 to 2027. Pricing analysis is included in the report according to each type from the year 2016 to 2027, manufacturer from 2016 to 2021, region from 2016 to 2021, and global price from 2016 to 2027.

A thorough evaluation of the restrains included in the report portrays the contrast to drivers and gives room for strategic planning. Factors that overshadow the market growth are pivotal as they can be understood to devise different bends for getting hold of the lucrative opportunities that are present in the ever-growing market. Additionally, insights into market expert’s opinions have been taken to understand the market better.

The research report includes specific segments by region (country), by manufacturers, by Type and by Application. Each type provides information about the production during the forecast period of 2016 to 2027. by Application segment also provides consumption during the forecast period of 2016 to 2027. Understanding the segments helps in identifying the importance of different factors that aid the market growth.

Source: https://reports.valuates.com/market-reports

India’s drive for greener mobility is underscored by lithium-ion battery advancements and government initiatives like PLI schemes and waste management rules, fostering EV production and sustainability.

Lithium-ion battery energy storage holds the potential to aid India in reaching its greenhouse gas reduction goals, as these batteries are essential for manufacturing electric vehicles due to their reliance on lithium and other crucial materials. Currently, India has minimal investments in Advanced Chemistry Cells (ACCs) production, resulting in a heavy reliance on imported ACCs to meet domestic electric vehicle battery demands. To decrease this dependence on imported ACC batteries, the Indian Government sanctioned a Production Linked Incentive (PLI) Scheme on May 12, 2021. This scheme allocates a total budget of Rs. 18,100 Crore over 5 years and aims to establish a competitive manufacturing ecosystem for ACC batteries in the country, targeting a capacity of 50 GWh. Moreover, the scheme includes provisions for 5GWh of specialized ACC technologies. Manufacturers who set up production facilities will receive a production-linked subsidy based on a per kWh subsidy rate and the percentage of value addition achieved through actual sales.

The Ministry of Heavy Industries in India has implemented several measures to promote the production of electric vehicles, including public transport buses, within the country:

1. FAME India Scheme (Phase-II): The Indian Government introduced Phase-II of the FAME India Scheme, which began on April 1, 2019, with an allocated budget of Rs. 10,000 crore. This phase was subsequently extended by 2 years until March 31, 2024. The scheme provides incentives to purchasers of electric vehicles by directly reducing the upfront purchase cost of such vehicles.
2. Production Linked Incentive (PLI) Scheme for Automotive Sector: On September 15, 2021, the Indian Government approved the PLI Scheme for the Automotive Sector, allocating Rs. 25,938 crores for it. This scheme encompasses electric vehicles as well.
3. Battery Waste Management Rules (2022): The Government of India, through the Ministry of Environment, Forest and Climate Change, released the Battery Waste Management Rules on August 24, 2022. These rules are designed to ensure the environmentally responsible management of waste batteries, including those from electric vehicles.These rules establish an Extended Producer Responsibility framework, which places the responsibility on battery producers to recycle or refurbish waste batteries within specified timeframes. The regulations also mandate that recyclers recover a minimum percentage of materials from these discarded batteries.

After a thorough and demanding evaluation process, Centrica has chosen TVS SCS as its preferred service partner to manage and transform its crucial supply chain operations.

TVS Supply Chain Solutions (TVS SCS) is a global supply chain solutions provider with an FY 23 revenue of over $1.2 bn. It is one of the largest and fastest growing integrated supply chain solutions providers in India according to the report titled ‘Logistics and Supply Chain Solutions Market in India’ prepared by Red Seer announced that it has secured a business deal from the iconic Centrica plc–an FTSE100 company with annual revenues of £34bn and UK’s leading energy services and solutions company that also operates British Gas -for their supply chain transformation. This deal is for 7 years plus option years.

After a rigorous evaluation process, Centrica found TVS SCS to be the right service partner to manage and transform its supply chain operations. TVS SCS, on its part, will provide its global supply chain expertise and offer a suite of its in-built, state-of-the-art proprietary IT systems –Msys – and automate the supply chain in line with Centrica’s business requirements. 

Ravi Viswanathan, Managing Director, TVS Supply Chain Solutions says, “The trust shown by Centrica (British Gas), to us through this deal demonstrates our capabilities and expertise in the world of supply chain solutions. I am sure this partnership with Centrica will add value to their energy services and solutions business, British Gas, through our tech-enabled supply chain solutions. We look forward to a fruitful and enduring collaboration that will benefit both the organisations and make a positive and lasting impact on the communities we serve.”

David House, Chief Operating Officer, British Gas, said, “We are delighted to be working in partnership with TVS SCS, a renowned leader in their field, as we embark on a transformative journey in our supply chain management. This strategic collaboration marks a pivotal moment for Centrica as we enhance our capabilities to deliver exceptional energy services and solutions to our valued customers. We are confident that TVS SCS’ solutions will enable us to create a seamless customer experience and drive operational efficiency. We look forward to a successful collaboration that will unlock new opportunities and drive growth.”

This transformational deal will enable Centrica to consolidate its logistics footprint through a new Centre of Excellence campus, supported by state-of-the-art automation; digital ordering and fulfilment; end-to-end visibility and planning; and a flexible final mile delivery and returns service.

TVS SCS, through its UK operations, manages Circa 3 million items per day for customers across automotive, beverage, defence, healthcare, rail, and utility sectors. These clients rely on TVS SCS’ ability to create and manage a resilient supply chain that actively mitigates the risk of supply from global disruptions. 

It offers a range of solutions, including consultancy, product data management, strategic purchasing, data analytics, inventory management, warehousing, and last-mile delivery. TVS SCS operates through 45 locations across the UK with around 3000 employees. 

A forging die lubricant is a chemical compound designed with a specific formulation to conduct the forging process within the established limits and parameters set by the forging industry.

Lubrication is crucial in ensuring the quality and productivity of the hot forging process, which operates at exceptionally high temperatures. For instance, hot forging occurs at temperatures as high as 1250 degrees Celsius, while Al-alloys are forged at 360 to 520 degrees Celsius and Cu-alloys at 700 to 800 degrees Celsius. 

These extreme temperatures are necessary to avoid strain hardening of the metal during deformation. Consequently, selecting the appropriate lubricants for specific application areas is essential to achieve optimal outcomes, making lubrication a challenging but indispensable task in the hot forging process.

A forging die lubricant is a chemical compound designed with a specific formulation to conduct the forging process within the established limits and parameters set by the forging industry.

Characteristics of ideal lubricants are as follows: 

• Reduce the sliding friction between dies and the workpiece (Load and energy requirement will be reduced). 

• Works as a parting agent between the die and workpiece. (Prevents sticking). 

• Works as an insulator. 

• It should develop a balanced gas pressure (Especially in hammer forging with the impression (this is called Dieseling effect). 

• Should be Non-Abrasive and Non-corrosive. 

• Shouldn’t create smoke (Pollution free). 

• Availability with reasonable cost. 

Die lubricants can be categorized into two main types based on the application areas, component profile, and metallurgy of the forging: water-based and oil-based. Each of these types further subdivides into variants with graphite and without graphite.

Water-based graphite lubricants: This type of die lubricant is a suspension that combines ultrafine graphite powder with specific additives and water. It is widely known and extensively used due to its popularity. The lubricant can be applied through spraying, brushing, or manual daubing. It is particularly suitable for demanding and essential press forging operations. Notably, this type of lubricant can be highly diluted in water, making it cost-effective for lubrication per tonnage while prolonging the die’s lifespan.

Water-based non-graphite lubricants: These lubricants are unique water-soluble polymer-based formulations, ideal for shallow cavity dies. They are widely regarded as the most cost-effective option because of their exceptional cooling and lubricating properties.

Other Products 

Oil-based lubricant: For the lubrication demands in the forging process, special additives are blended with graphite, using either base oil or vegetable oil as a base. This creates the suspensions mentioned earlier. Some graphite-free variants still offer exceptional release properties and improved material flow. These versatile lubricants find utility in various applications, including deep cavity hammer forgings, heavy stainless-steel forgings, critical brass and aluminium forgings, and deep extrusions.

Spray guns & spraying equipment: Sunlub Technologies provides a comprehensive selection of die lubricants along with cost-effective application solutions through Spray Guns & Spraying Equipment. Their offerings include Single side & Dual side spray guns, Spray systems with pressure feeder tanks (45 & 75 Litres capacity), and Spray systems with open tanks (100 & 200 Litres capacity) equipped with AODD pumps. Sunlub Technologies maintains a widespread sales network throughout India to ensure efficient service and quick response.

Contact us:
Sunlub Technologies
Plot No. L-89, MIDC Industrial Area, Ahmednagar, Maharashtra – 414111
www.sunlubtechnologies.com; info@sunlubtechnologies.com
8181 819 531