Sunday, 18 December 2011

Episode Five Show Notes / Transcript

http://traffic.libsyn.com/australianptpodcast/ep5ozpt.mp3


Episode 5 Australian Power Transmission Podcast

In this episode

                The Thompson Coupling

                B2B social media – my quick thoughts

Thanks for tuning in to the fifth episode of the Australian Power Transmission Podcast, Monday December 19, 2011.  I’m Damian Harris, I’m in Melbourne.

Contact the Australian Power Transmission Podcast via the following methods: twitter @ozpotpodcast, email ozptpodcast@aol.com and comments on the web australianptpodcast.blogspot.com. 



*The Italian Bonfiglioli Group is looking to end 2011 with strength, recording net revenues of 680 million Euros across all strategic business units.  There has been a major shift in sales distribution, with sales from European markets dropping from 458 to 400 million Euros, while emerging markets helped Bonfiglioli post a 13% sales jump from 2010. Bonfiglioli has identified consistent Research and Development – even during the European financial downturn – as being a major factor in the turnaround.

Strong demand in the wind energy sector has been beneficial to overall sales, as well as heavy machinery and agricultural equipment – two traditional stalwarts of Bonfiglioli revenue.

*Dwarfing Bonfiglioli’s sales is the result by ZF Friedrichschafen AG, the German gearing engineering and manufacturing firm that specialises in the automotive sector.  ZF Group recently acquired Hansen Transmissions of Belgium on its way to an overall result of 15.5 billion Euros for 2011.

ZF joins its major competition in identifying wind turbines, electric hybrid technology and an increase in production capacity in developing nations as strategic growth initiatives.  ZF should also be commended for reaping the rewards of consistent investment in R&D. 

*The Australian government has had a cabinet reshuffle, with a few portfolios playing switcheroo.  Former Minister for Innovation Senator Kim Carr has been removed from this central role, to be put in charge of the new Ministry for Manufacturing.  Innovation now becomes part of a super ministry, officially titled the Department of Industry, Innovation, Science, Research and Tertiary Education – somehow implying all of these are linked.  The large ministry will be handled jointly by Greg Combet MP and Senator Chris Evans, while Mark Dreyfus MP will be appointed Parliamentary Secretary for Industry and Innovation, supporting Minister Combet.

Various Australian state governments have ministers for manufacturing, which are normally lumped in with innovation and trade.  As a separate ministry, I’m not sure how Senator Carr is going to make manufacturing his own.  I’m certain that the Minister will have a significant role in the Prime Minister’s newly-created taskforce on keeping the manufacturing sector employed, as well as a bit of ribbon cutting, but a Minister of Manufacturing and a Minister of Industry will surely have too much crossover to work effectively.

Already, Senator Carr has organised meetings in the US to see the bosses at GM and Ford to tee up funding for the local subsidiaries.  Both manufacturers are in a difficult position in Australia and will probably require Senator Carr to turn up with an open wallet when he visits next month, and not vice versa.

*Only a short time has elapsed since the announcement that Altra Industrial Motion had purchased Bauer Gear Motor, but that hasn’t stopped the powers that be in Braintree from searching out possible synergies with existing brands and technologies.  Altra announced the 2000 series of helical bevel gearboxes and integral gear motors, utilising experience and knowledge from both Bauer and Boston Gear.

The 2000 series looks to be pitched at the food manufacturing industry, with many of its features assisting washdown and corrosion resistance.  Utilising both IEC and NEMA motor frames is a smart move and should allow universal acceptance on both sides of the Atlantic.  It isn’t clear if Australia will be a recipient.

I am a little disconcerted that one of the key promotional points that Altra has chosen to run with is the fact that the 2000 series is a direct ‘drop-in’ replacement for the SEW-Eurodrive KA series of gearboxes.  Some of Altra’s promotional material states that in designing the 2000 series, product specialists asked customers what they wanted in a geared motor design.  The answer was obviously they wanted the KA series by SEW!

*South Australian Harley-Davidson subsidiary New Castalloy has been given an 18 month death sentence by its Milwaukee parent, as the motorcycle giant closes the plant in favour of having its wheels made in the US and Japan.

212 staff will go from the North Plympton manufacturing facility and although profitable, the usual issue of exchange rates has been put forward as a contributing factor for the close, as well as the ending of a financial agreement between Harley-Davidson and the South Australian government.

Harley-Davidson had pretty much rescued Castalloy in 2006 when it was on the verge of going broke and has had the bulk of its wheels produced there since.

*The Chief Executive of the Australian Industry Group – Heather Ridout – is soon to be the former Chief Executive of the Australian Industry Group as she resigns her post in favour of a position on the board of the Reserve Bank of Australia.  The Australian Industry Group represents all areas of Australian business, with a focus on manufacturing and industry. 

The role that Ms. Ridout has played in Canberra cannot be underestimated as the chief lobbyist for the manufacturing sector and it will be interesting to see if her successor will come from within the ranks of the 300 staff currently employed at AI Group or if someone from outside will be headhunted.

*As announced in the inaugural Australian Power Transmission Podcast, BlueScope Steel had decided to reduce production in line with flagging demand at both Port Kembla and Hastings, laying off 1000 workers in the process.  The same episode also had details of Australia’s new carbon tax, and how it was going to affect business.  Well, combine the two and you get the next news item.

BlueScope has applied to the federal government for $100M of industry assistance, under the Steel Transformation Plan, which is aimed at helping to offset the carbon bills as they roll in but is in effect a way to keep the doors open at a major employment source in disparate areas of the country.

 The Thompson Coupling is the brainchild of Glenn Thompson, an Australian from rural New South Wales who has rethought the constant velocity joint and invented a shorter and more efficient way of joining high-misalignment shafts together.

To be more correct with Thompson’s invention, there are two products that his company markets from its Orange, New South Wales premises; namely the Thompson Constant Velocity Joint and the Alignment Eliminator pump coupling range.  The Thompson Constant Velocity Joint would appear to be the backbone of the design’s future, being used in high-torque applications for rail infrastructure and miscellaneous industrial functions, whilst the Alignment Eliminator is an off-the-shelf offering for high-misalignment pump applications up to 73kW.  The Alignment Eliminator is more in keeping with the purview of the Australian PT Podcast so I will focus my attention on it.

The Alignment Eliminator will handle up to six degrees of misalignment in axial, offset and angular configuration and there are four sizes in the range, handling from up to 10kW through to up to 75kW.  Like many gear couplings, the Alignment Eliminator must not be perfectly aligned and requires some misalignment to function correctly.  The fact that it can cope with higher misalignment means that it can be fitted and set up in a much shorter time than couplings requiring proper aligning with lasers.

The smart design of the Alignment Eliminator has patents on the go all across the world, and Thompson is currently looking at licence agreements for manufacture and distribution, to supplement what is produced locally.  I know that this segment sounds like an advertisement for the Thompson Coupling but I’m really impressed with what it can do.  I’m not the only one, as Boeing has signed a long-term development contract as they look for ongoing applications.

In Australia, the distributor of the Alignment Eliminator is Southern Engineering Services out of Wollongong, New South Wales.

As I say at the top and bottom of every show, you can contact the Australian Power Transmission Podcast on twitter as well as through comments on the website or via email.  It got me to thinking how popular twitter is with marketers, so I thought I’d do a bit of research into its reach for the Business to Business audience.

Twitter (and social media in general) is something of an unknown quantity in the B2B world, whilst being almost invisible in the field of mechanical power transmission.  There are a few bearing retailers and electric motor rewinders who have a twitter profile and are fairly active, but none of the world’s gearing manufacturers have bothered with the medium.

Taking the next step in the social media landscape, Facebook has business pages that offer a way for consumers to deal directly with businesses and vice versa.  In mechanical power transmission, it’s almost a ghost town.  SEW, WEG, Baldor, Sumitomo and Altra have pages, but the content is simply a direct rip from their corresponding Wikipedia page.  There are no site administrators for any of these pages, by the looks of it, and there isn’t really a way to contact them.

From my investigation, no one else has put anything on their Facebook page, making searching for them nigh on impossible and leaving a gaping hole of a marketing opportunity.  I know I’m sort of preaching to the converted because you are listening to this podcast and are probably aware of everything to do with twitter, Facebook, Google+, YouTube and a myriad of other social media platforms and even how they can be used for B2B dealings.  It’s just funny that some of the big multinationals will spend megabucks on advertising campaigns, tradeshows, classy websites and more, yet social media – and its’ relatively little cost, sails through to the keeper.

Of all manufacturers using social media, Bishop-Wisecarver does one of the better jobs of engaging with its community.  The Pittsburg, California manufacturer of linear motion guide wheels is all over twitter with close to 6000 tweets, has an active YouTube channel and of course actually has a Facebook page.  I wouldn’t call linear motion guide wheels the sexiest technology to be in, yet these guys do a fantastic job that I’m sure creates more in sales than it costs per annum.

Business to Business customers aren’t looking at retail type social media marketing efforts, but I think that the scope exists for manufacturers to at least get involved.
 
That’s it for the fifth episode of the Australian Power Transmission Podcast.  Email me ozptpodcast@aol.com, tweet me @ozptpodcast, comments on the web australianptpodcast.blogspot.com, iTunes, not Facebook yet, not Google+ yet.

The Australian Power Transmission Podcast is going to have a break until after the Christmas holidays.  The PT world shuts down over this period and there isn’t too much news to tell so I’m going to have a breather too.  Having said that, if something major breaks I will be right on top of it and put something straight to the airwaves.

Thanks for all of your support and I will look forward to you company in four weeks, maybe six... I’ll let you know.

Episode Five of the Australian Power Transmission Podcast

Play it directly in the browser or download the link...

http://traffic.libsyn.com/australianptpodcast/ep5ozpt.mp3

In this episode:

Bonfiglioli's 2011 financial result

ZF Friedrichschafen AG result

Australian Government cabinet reshuffle

Bauer - Boston Gear collaboration

Harley-Davidson shuts New Castalloy

Heather Ridout joins the RBA, leaves AI Group

BlueScope sticks its hand out

The Thompson Coupling

B2B social media

Wednesday, 7 December 2011

Heather Ridout Resigns from Australian Industry Group

Heather Ridout (featured in the news section of Episode 4) is standing down from her role as CEO of the AI Group and Australian manufacturing's lone voice in Canberra, before taking up a role on the board of the Reserve Bank of Australia.

Ms. Ridout has been in charge at AI Group for 8 years and her successor is yet to be announced.

Australian manufacturing needs to continue to lobby hard politically, in the same way that mining and health have done during the current government.  For example, Australian taxpayers continue to subsidise diesel fuel for the mining sector, even during the boom currently being experienced.

Sunday, 4 December 2011

Episode Four Show Notes / Transcript

Download the episode here...



Episode 4 of the Australian Power Transmission Podcast

In this episode

                Minimum Energy Performance Standards, and

                Lubrication examined, if only briefly

Thanks for joining me for the fourth episode of the Australian Power Transmission Podcast, coming to you from Melbourne but covering the whole of Australia with an eye on the world of power transmission.  My name is Damian Harris and it is Monday December 5, 2011.  In answer to some listener questions, Uncle Seth is playing me in and it is their song ‘Get Out Of My Face’ that features in the outro as well.

Take advantage of contacting the show – our operators are standing by.  Twitter @ozptpodcast, email ozptpodcast@aol.com, web australianptpodcast.blogspot.com.

What’s been going on?

News

* The Power Transmission Distributors Association (PTDA) elected its 2012 Board of Directors and Manufacturer Council in Washington, DC in October at their Industry Summit.

Mitch Bouchard of General Bearing Service succeeds David Mayer of Kaman Industrial Technologies.  The balance of the board comprises Christopher Bursack from Industrial Supply Co, Ken Miko from BDI and Keith Nowak of NPT Drives.

The Directorship is made up of Harold Dunaway of Motion Industries, LeRoy Burcroff of Bearing Service, Rick White of Flexco, Carlton Harvey of Jamaica Bearings, Ajay Bajaj of Rotator Products Limited and Thomas Clawser of Brown Transmission and Bearing Co.

George Rizza – who is the President of Rossi Gearmotor Division, Habasit America – takes over from Pamela Kan of Bishop-Wisecarver as PTDA Manufacturer Council chair. 

The male-domination of the industry in general is directly reflected by the make-up the both the board of the PTDA and the Manufacturer Council.

Representing 178 power transmission distributors across 11 countries, the Power Transmission Distributors Association has a stated mission of advancing distribution and strengthening members to be successful, profitable and competitive in a changing market environment.’

* Chief Executive of the Australian Industry Group – Heather Ridout – addressed  the National Press Club in Canberra on November 30th.  Titled ‘Taking Charge of Our Future’, Ms. Ridout acknowledged the high-cost and multi-speed economy as being burdensome to local manufacturing, before offering some ideas for possible restructuring in the sector.  After teeing off on some of the federal government’s recent workplace relations decisions which she feels to be too heavily slanted to favour unions, the biggest takeaway point was probably the support Ms. Ridout gave to the government’s mining tax.

* The Canadian Manufacturing Technology Show 2011 was held in Toronto at the end of October, proving to be a moderate success if the Twitter stream is anything to go by.  Manufacturing accounts for 13% of Canada’s GDP (Australian manufacturing represents 10% of GDP) and the two economies are very similar, in that there is a large reliance on natural resources.

For the show itself, SEW-Eurodrive dominated power transmission proceedings and over six and a half thousand people filtered through the Direct Energy Centre over four days.

*Brazil continues to offer a very attractive home for power transmission capital investment, with Japan’s Sumitomo Heavy Industries investing $73M in a new gear reducer manufacturing plant.  Opened late November, the plant joins similar SHI facilities situated in developing economies – a stated growth strategy of the organisation.

Brazil has been economically unstoppable for the past few years and I think we are going to see even more announcements like this one from Sumitomo.

*The Victorian Minister for the Aviation Industry was front and centre for the recent announcement that Melbourne would provide Boeing GoldCare maintenance services to the Asia-Pacific region.  Boeing chose John Holland Aviation Services to look after its B737NG fleet as well as the 787 Dreamliner.

John Holland is the new name of the former Ansett Engineering and although aviation engineering is a specialist field, power transmission equipment features heavily throughout the maintenance process.

* The Prime Minister’s Manufacturing Taskforce held its first meeting in late November.  Tasked with securing a working future for over one million Australian manufacturing workers, the Taskforce concluded that there are many serious issues facing manufacturers and that something should be done to help them.

In all seriousness, the Taskforce concluded that existing state and federal policies need to be better co-ordinated and leveraged, science and technology were going to be the leading forces and management of the entire process was critical.

*As reported in episode two of the Australian Power Transmission Podcast, BHP-Billiton was given the green light to expand its Olympic Dam mining operations.  Controversially, Olympic Dam sits atop significant reserves of uranium.

It comes as little surprise that only weeks after the go ahead was given to exploit Olympic Dam, the leader of the ruling Australian Labour Party and current Prime Minister, Julia Gillard, has announced her intention to overturn the ALP’s 30-year ban on selling uranium to India.








*Said to account for 30% of electricity consumption in Australia, electric motors are the mainstay of the industrial sector, performing every task from mixing and conveying to pumping and crushing.  For the most part, these motors have done their job with an efficiency in the 80-90% range, but governments the world over are seeing what benefits are on offer by increasing this efficiency percentage into the mid 90s.

Minimum Energy Performance Standards were introduced at the turn of the century by the Australian and New Zealand governments for a wide range of electrical equipment.  For electric motors, a rating of MEPS 1 came into effect in October 2001, whilst the higher efficiency MEPS 2 superseded MEPS 1 in 2006.

All three phase electric motors that are either made in or imported into Australia must comply with the minimum efficiencies as set out by the MEPS ratings.  When I say all motors, the sizes covered range from 0.73kW to 185kW in 2, 4, 6 and 8 pole configuration, which for all intents and purposes may as well be all motors.

There are some exceptions to the MEPS rule.  MEPS doesn’t apply to submersible motors, integral motor-gear systems – like those available from Bonfiglioli, SEW and Nord – variable and multi-speed motors or motors rated less than continuous duty.  Motors that have been rewound are also not required to comply with MEPS.

Motor manufacturers have not shied away from the responsibilities of meeting efficiency standards around the world.  The standard measure for increasing efficiency has been to use larger, lower-resistance winding wire and higher quality steel for laminations.  When coupled with total motor re-designs, the efficiency standards have been able to be met on a consistent basis.

One of the benefits of the new, high-efficiency motor range is that they also have improved performance at part load, making them extremely suitable for variable speed drive service.  Many major manufacturers are taking advantage of this fact by matching motors and drives in their product offerings.

There have been many sets of figures bandied around by different groups – all with an agenda and all relating to the savings from the introduction of MEPS.  Regardless of the source, common wisdom points to an overall cost / benefit ratio of 1.8.

California led the way with minimum efficiency standards, empowering the Californian Energy Commission to regulate electric equipment over 30 years ago.  Since this time, the US has led the world in electrical energy efficiency and looks to continue in the same vain for a long time.  This is in stark contrast to the common assessment of American cars, colloquially labelled Gas Guzzlers and Yank Tanks. 

Further developments in efficiency standards for electric motors are always on the agenda and will continue to keep manufacturers on their toes.




* For all of the tribologists out there, here’s a quick overview of lubrication in the geared motor industry.

The lubrication industry is probably worthy of its own fortnightly podcast.  A lot is spent on research and development and competition is fierce among the major players in the industry.

Lubrication in enclosed gear drives is a very explicit niche of lubrication, where four specific parameters must be met, namely; gear wear protection, water separability, corrosion protection and foaming resistance.

Geared motor manufacturers are continually pushing the envelope with their designs, trying to get the highest input power and largest output shaft into the most compact unit possible.  All of which places greater demands on the lubrication used.

Gear wear protection is the primary function of lubricants in gearboxes, but the same oil must also lubricate the bearings and rolling elements.  This presents something of a compromise to some of the properties of the lubricant and which additives can be added.

Extreme Pressure (or EP) additives are introduced when gearbox loads may overcome the viscosity of standard oil and cause higher than normal gear and bearing wear.  These additives create a film on the metal surfaces to prevent direct contact and can be used in conjunction with solids such as molybdenum disulphide to create a physical metal-to-metal contact barrier.

 Water separability or demulsibility is a major requirement of gearbox lubricant, where liquids such as coolant and condensation come into contact with the gearbox oil and must be easily removable.

Demilsifiers are added to ensure that water cannot emulsify with the gearbox oil, using some pretty impressive chemistry in the process.

Corrosion protection is important in gearbox lubricant, due to the fact that many gear units utilise yellow metals such as copper and brass as well as cast iron.  This creates something of a problem, as many features of rust protection for cast iron are chemically-aggressive to the softer yellow metals.

The ability to resist foaming is also extremely important in gear oils. Foaming results from the natural movement of gears and is especially prevalent in high speed applications.  Polymers are added to change to surface tension of the lubricant, killing bubbles as they form.

Different loads and temperature effects require differing types of oil.  For low load applications in standard temperatures, a straight mineral oil is adequate.  When the load increases, a mineral oil with EP additives might be required.  As the conditions become more demanding, synthetic lubricants come into their own.

Once again, there are different types of synthetic lubricants for differing applications.  Polyglycol synthetic lubricants with EP additives such as Shell Tivella are a general synthetic lubricant for wormboxes.  Most off the shelf wormboxes like the Bonfiglioli W series run this type of lubricant and are basically sealed for life in applications where running conditions are less than 40 degrees Celsius above ambient.

Polyalphaolefin synthetic lubricants with EP additives like the very popular Shell Omala will give approximately four times the working life of mineral oil in the same application.  These are normally specified in bevel-helical and in-line helical gearboxes.

Other things to be considered when specifying gearbox oils are whether there will be food contact or bio-degradable qualities required.  All of these properties are specified by the major manufacturers to aid comparison.

I won’t go into too much more detail about oils and lubrication because it is a massive subject and I want to do it justice by going further in a future episode.

* That wraps up the fourth instalment of the Australian Power Transmission Podcast.  I’m Damian Harris, contactable on twitter @ozptpodcast, email ozptpodcast@aol.com and via the web australianptpodcast.blogspot.com.

Thanks for everyone’s support, all the downloads, listens, etc.  Leave a review on iTunes, good or bad, all feedback is appreciated.

Before I go I would just like to thank some of the podcasting professionals who have supplied free resources for people who are getting into podcasting.  In no particular order, thanks to Daniel J Lewis, Dave Jackson, Dave Thackeray, Cliff Ravenscraft, Ray Ortega and Max Flight.
I’ll look forward to your company in two weeks.



Episode Four is on the airwaves

Check it out here...