Sensors and Tribological Systems: Applications for Industry 4.0

Purpose: The involvement of wear, friction and lubrication in engineering systems and industrial applications makes it imperative to study the various aspects of tribology in relation with advanced technologies and concepts. The concept of Industry 4.0 and its implementation further faces a lot of barriers particularly in the developing economies. Real-time and reliable data is an important enabler for implementation of the concept of Industry 4.0. For availability of reliable and real-time data about various tribological systems is crucial in applying the various concepts of Industry 4.0. This paper attempts to highlight the role of sensors related to friction, wear and lubrication in implementing Industry 4.0 in various tribology related industries and equipment. Design/methodology/approach: A through literature review has been done to study the interrelationships between the availability of tribology related data and implementation of Industry 4.0 are also discussed. Relevant and recent research papers from prominent databases have been included. A detailed overview about the various types of sensors employed in generating tribological data is also presented. Some studies related to application of machine learning and Artificial Intelligence are also included in the paper. A discussion on fault diagnosis and cyber physical systems in connection with tribology has also been included. Findings: Industry 4.0 and tribology are interconnected through various means and the various pillars of industry 4.0 such as big data, Artificial Intelligence can effectively be implemented in various tribological systems. Data is an important parameter in effective application of concepts of industry 4.0 in the tribological environment. Sensors have a vital role to play in the implementation of industry 4.0 in tribological systems. Determining the machine health, carrying out maintenance in off-shore and remote mechanical systems is possible by applying online-real-time data acquisition. Originality: The paper tries to relate the pillars of Industry 4.0 with various aspects of tribology. The paper is a first of its kind wherein the interdisciplinary field of tribology has been linked with industry 4.0. The paper also highlights the role of sensors in generating tribological data related to the critical parameters such as wear rate, coefficient of friction, surface roughness which is critical in implementing the various pillars of industry 4.0

The role of additive manufacturing in industry 4.0: An exploration of different business models

Purpose The rising interest in the integration of digital advanced manufacturing and production systems in the Industry 4.0 context is one of the main factors in the introduction of Additive Manufacturing (AM). The novel technology might change the way firms operate, and the way they interact with consumers, opening new horizons for an improved profit margin and more sustainable business models. The research presented a comprehensive review on the potent role of AM in adhering to customers’ complicated and unique needs using various technologies and techniques, as it discussed the role of AM in introducing new business models that increase the business competitiveness and profitability through an optimisation of production processes. In addition, AM is grasping with innovative solutions varying from waste reduction to shorter supply chains to longer products lifecycle, incentivising firms to adopt it for the economies realised on materials, energy, and costs. Notwithstanding, AM implementation is still in its infancy and faces technical challenges of capability, IT integration, and outcomes. Design/Methodology/approach This research is based on a quantitative approach that was administered online by means of a highly structured online survey, which aim was to collect primary data that fills the gaps of the research hypotheses due to the lacking nature of research papers exploring them. Therefore, the literature review was a paramount phase in acquiring empirical knowledge about the problem background and concept boundaries that shaped the topic's core objectives and research questions from the lacking nature of explored areas. Findings This research investigated the role of AM in industry 4.0 by exploring its impact and intersection with AM firms’ business models while exposing the limitations and challenges to its adoption within industrial contexts. The study highlighted that the AM positive impacts on companies’ business models on the value chain and turnover. This study also revealed the eco-design prospect of AM that will be helpful for different firms to rethink their business models shaping them to be more cost-efficient. Originality This research gave insight on AM technology through a quantitative survey that mainly aimed to classify knowledge and to investigate the role of AM as a lever in improving firms’ value chains through an exploration of possible intersections with business models and impacts of implementation, possible sustainability scenarios and challenges it may face within Industry 4.0 context

The role of additive manufacturing in industry 4.0: An exploration of different business models

Purpose: The rising interest in the integration of digital advanced manufacturing and production systems in the Industry 4.0 context is one of the main factors in the introduction of Additive Manufacturing (AM). The novel technology might change the way firms operate, and the way they interact with consumers, opening new horizons for an improved profit margin and more sustainable business models. The research presented a comprehensive review on the potent role of AM in adhering to customers’ complicated and unique needs using various technologies and techniques, as it discussed the role of AM in introducing new business models that increase the business competitiveness and profitability through an optimisation of production processes. In addition, AM is grasping with innovative solutions varying from waste reduction to shorter supply chains to longer products lifecycle, incentivising firms to adopt it for the economies realised on materials, energy, and costs. Notwithstanding, AM implementation is still in its infancy and faces technical challenges of capability, IT integration, and outcomes. Design/Methodology/approach: This research is based on a quantitative approach that was administered online by means of a highly structured online survey, which aim was to collect primary data that fills the gaps of the research hypotheses due to the lacking nature of research papers exploring them. Therefore, the literature review was a paramount phase in acquiring empirical knowledge about the problem background and concept boundaries that shaped the topic’s core objectives and research questions from the lacking nature of explored areas. Findings: This research investigated the role of AM in industry 4.0 by exploring its impact and intersection with AM firms’ business models while exposing the limitations and challenges to its adoption within industrial contexts. The study highlighted that the AM positive impacts on companies’ business models on the value chain and turnover. This study also revealed the eco-design prospect of AM that will be helpful for different firms to rethink their business models shaping them to be more cost-efficient. Originality: This research gave insight on AM technology through a quantitative survey that mainly aimed to classify knowledge and to investigate the role of AM as a lever in improving firms’ value chains through an exploration of possible intersections with business models and impacts of implementation, possible sustainability scenarios and challenges it may face within Industry 4.0 context

High Cyclic Fatigue Behaviour of Varied Pitch Compression Springs for Automotive Applications

In this paper, fatigue life of coil springs was investigated as failure due to high cyclic loading during their service life is more common. For this purpose, two exclusive rear coil compression spring geometries were investigated using material type - siliconchromium steel SAE-AISI 9254 for this application. For these design models, the effect of changing component geometry using varying pitch arrangements of coils were examined to understand their structural durability and ability to withstand cyclic loading conditions. A finite element model based on industry standard designs was created to simulate real-life spring performance. In this study, the varied pitch designs were subjected to lower stresses in static analysis and have longer life estimates in the fatigue analysis. This confirms that a varied pitch can improve the performance of a coil spring. The result shows that design-1 incorporated a pitch design that reduced pitch at the centre coils of the spring performed better

Production and Maintenance in Industries: Impact of Industry 4.0

Purpose: Production industries are undergoing a digital transition, referred to as the fourth industrial revolution or Industry 4.0, as a result of rapidly expanding advances in information and communication technology. The purpose of this research is to provide a conceptual insight into the impact of unique capabilities from the fourth industrial revolution on production and maintenance tasks in terms of providing the existing production companies a boost by making recommendations on areas and tasks of great potential. Design/methodology/approach: A survey and a literature review are among the research methods used in the research. The survey collected empirical data using a semi-structured questionnaire, which provided a broad overview of the company's present condition in terms of production and maintenance, resulting in more comprehensive and specific information regarding the study topics. Findings: The study points out that, the implementation of I4.0-technology leads to an increase in production, asset utilization, quality, reduced machine down time in industries, and maintenance. Sensor technology, big data analysis, cloud technologies, mobile end devices, and real-time location systems are now being implemented to improve production processes and boost organizational competitiveness. Moreover, the study highlights that data acquired throughout the production process is utilized for quality control, predictive maintenance, and automatic production control. Furthermore, I4.0 solutions help companies to be more efficient with assets at each stage of the process, allowing them to have a stronger control on inventories and operational-optimization potential. Originality: The findings of the study was supported by empirical data collected through survey that provides an intangible understanding of the importance of distinctive capabilities from the I4.0 revolution on production and maintenance tasks. In this study, some recommendations and guidelines to enhance these tasks are provided that are vital for existing production companie

Potential of AA7075 as a Tribological Material for Industrial Applications -A Review

Lightweight materials in general and alumunium alloys in particular are increasingly becoming important engineering materials in order to improve the sustainability aspects of engineering products. Amongst the alumunium alloys, AA7075, due to its strength to weight ratio along with other technical benefits has become a prominent material. The literature suggests that AA7075 is structurally good, however its poor tribological properties can be enhanced by introducing different reinforcements. Further, the mechanical and tribological behaviour of AA7075 relies on variety of factors such as fabrication route, quality and quantity of reinforcement, etc. In this work we summarize the work carried out in studying the various mechanical and tribological properties of AA7075. The paper will focus on the ceramic and solid lubricant reinforced AA7075 hybrid composites. A section also summarizes the applications of the alumunium alloys and composites in various engineering applications

Development of a NIOSH based software tool for musculoskeletal disorders

Musculoskeletal disorders amongst workers performing manual lifting tasks have become a major challenge now a days. Such problems hamper productivity of any concern to a greater extent. Industrial experts and researchers have been devising ways and means to reduce such disorders and the National Institute of Occupational Safety and Health (NIOSH) agency lifting equation is one amongst such tools. NIOSH lifting equation has significantly enhanced the safety of the workers involved in manual lifting tasks. With this equation, a prior indication of musculoskeletal disorders can be obtained from the workers anthropometric details. However, till date there is no such tool available with which we can have recommendations to eliminate/reduce such disorders. In this paper an expert system on the basis of NIOSH equation has been developed to deal with the musculoskeletal problems amongst the workers involved in manual lifting tasks. The expert system is basically a computer programme developed to facilitate the use of NIOSH lifting equation. On the basis of lifting parameters, this equation computes recommended weight limit (RWL) and lifting index (LI). These outputs have been further analyzed by the programe to check existing working conditions against occupational hazards, and suggest recommendations for the safe working conditions

Potential of AA7075 as a Tribological Material for Industrial Applications -A Review

197-201Lightweight materials in general and alumunium alloys in particular are increasingly becoming important engineering materials in order to improve the sustainability aspects of engineering products. Amongst the alumunium alloys, AA7075, due to its strength to weight ratio along with other technical benefits has become a prominent material. The literature suggests that AA7075 is structurally good, however its poor tribological properties can be enhanced by introducing different reinforcements. Further, the mechanical and tribological behaviour of AA7075 relies on variety of factors such as fabrication route, quality and quantity of reinforcement, etc.  In this work we summarize the work carried out in studying the various mechanical and tribological properties of AA7075. The paper will focus on the ceramic and solid lubricant reinforced AA7075 hybrid composites. A section also summarizes the applications of the alumunium alloys and composites in various engineering applications

Development of a NIOSH based software tool for musculoskeletal disorders

860-865Musculoskeletal disorders amongst workers performing manual lifting tasks have become a major challenge now a days. Such problems hamper productivity of any concern to a greater extent. Industrial experts and researchers have been devising ways and means to reduce such disorders and the National Institute of Occupational Safety and Health (NIOSH) agency lifting equation is one amongst such tools. NIOSH lifting equation has significantly enhanced the safety of the workers involved in manual lifting tasks. With this equation, a prior indication of musculoskeletal disorders can be obtained from the workers anthropometric details. However, till date there is no such tool available with which we can have recommendations to eliminate/reduce such disorders. In this paper an expert system on the basis of NIOSH equation has been developed to deal with the musculoskeletal problems amongst the workers involved in manual lifting tasks. The expert system is basically a computer programme developed to facilitate the use of NIOSH lifting equation. On the basis of lifting parameters, this equation computes recommended weight limit (RWL) and lifting index (LI). These outputs have been further analyzed by the programe to check existing working conditions against occupational hazards, and suggest recommendations for the safe working conditions