Stavanger Hospital Uses 3D Scanning and AI Throughout the Entire Construction Period

Stavanger Hospital | August 14, 2020

The new University Hospital in Stavanger, one of the biggest public construction projects in Scandinavia, adopted 3D scanning and AI technology to track work quality and avoid costly mistakes. In Stavanger, the fourth largest city in Norway, located about 300km from Oslo, the construction of the new university hospital is going at full speed. Hundreds of people work on the project, which covers 130,000 sq m. To closely keep track of the massive project, the developer SUS2023 has chosen to use 3D scanning and Artificial Intelligence throughout the entire construction period. Instead of manual inspections that can take days, or even weeks, everything is checked digitally and with millimetre accuracy. A single person digitises the job site and the entire team can have access to the results. To do so, the team uses a tech solution developed by Imerso, a start-up company based in Oslo. After the SUS2023 team scans the construction site, Imerso’s platform compares the laser scans against the BIM plans and immediately reports problematic work deviations.

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Machine learning is becoming increasingly popular with TDWI audiences. In recent surveys, we’ve seen the use of this technology (and its related technology: statistics for predictive analytics) in the early mainstream phase of adoption. Machine learning is being deployed in a wide range of use cases.


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MATERIALS

Aerospace and defense materials continue to challenge toolholding

cutting tool engineering | December 14, 2021

From Rene 41, 718 stainless steel and 625 Inconel to titanium and carbon fiber, the materials used in the aerospace and defense industry sector as well as space exploration continue to present significant toolholding challenges. Magnifying these challenges are complex workpiece geometries with deep cavities, features that require long tool overhangs, and jobs requiring small-diameter cutters. Toolholding is just as important as the machine that runs it, and sub-par tooling can keep a machine from running at its full potential. For these reasons, shops turn to high-quality, precise toolholding. Because many of these materials are hard on cutting tools, shops constantly strive for the longest possible tool life. For one shop, the simple switch to a high-precision mechanical-type toolholding system skyrocketed its tool life from machining 100 steel parts per cutter up to 700.Toolholder reduces TIR When it comes to toolholding, one key to increased cutter life is a holder that provides ultra-low Total Indicated Runout (TIR). The goal is to get as close to zero TIR as possible. With every 0.0001" of TIR reduction, the company says that tool life can increase by upwards of 50%. Another example when reduced cutter TIR is required are long tool overhangs to reach complex part features in parts that do not provide much clearance. Shops within the Aerospace, Defense and Space Exploration sectors often run cutters as small as 0.128" diameter in a CAT 40 machine tool spindles with the tools hanging out up to 8" from the spindle nose. To achieve TIR of 0.0002" and under in such overhang applications depends almost entirely on the precision of the toolholder. Part characteristics and features that involve 5-axis machining, such as those typically associated with 3D metal printed parts, compound the risk of cutter runout and breakage. In the Aerospace, Defense and Space Exploration sectors, 3D metal printed parts made from materials such as 718 Inconel and titanium are commonplace, and some of these parts can take as long as 40 hours to produce. Shops have one chance to machine them correctly, and must use toolholders that not only provide low TIR, but also offer the necessary strength and stability. Cutters create dillemma In addition to challenging parts, solid ceramic cutters for machining nickel-based and other heat-resistant alloys present a dilemma for shops in the aerospace, defense and space sectors.. Solid ceramic cutters generate significant amounts of heat that can affect the holding integrity of certain types of toolholders. For instance, toolholders that use heat or hydraulics for clamping would be at risk from the higher-than-normal levels of heat generated during machining with ceramic tools. Mechanical-based systems, however, are unaffected by extreme heat. Beyond the challenges of metal workpieces, those produced from carbon fiber composites also cause issues with tool life and for toolholding. Shops must use tools designed specifically for the materials, which are extremely abrasive. While cutting, these tools force the part material downward and upward simultaneously to prevent delamination of layers. When holding these tools, maintaining low TIR is once again critical to achieving part quality and the longest-possible tool life, but tool pullout is also a major concern, especially when shops want to run cutters at maximum rpm. To combat this, toolholders need tremendous gripping strength paired with some type of locking tool-retention mechanism. CO2-based cooling Because shops cannot use conventional coolant when machining carbon fiber composites, many have incorporated the use of CO2-based cooling systems. These systems use supercritical CO2 not only to cool, but also to lubricate and to evacuate chips. Not all toolholders are suited for CO2 coolant delivery, and with some, tool changeovers can be time consuming as well. Combined with the latest cutting tool technology and the right toolholders, CO2 cooling systems can provide productivity increases in the 70% range. Compared to shrink-fit toolholding systems, mechanical-based systems offer optimum CO2 delivery and the fastest, easiest tool changeovers. For heat shrink, the delicate ruby nozzles used to deliver the CO2 to cutters would need to be removed prior to heating the holder to change out a tool – a task that can require hours. Conversely, some mechanical toolholding systems incorporate modified collets specifically for either through-tool or external CO2 cooling that have no effect on tool changeout time. CO2 coolant also can be supplied through modified toolholding collets with 150µm slots that direct coolant around the shank and along the exterior sides of a composite tool. CO2 cooling offers especially beneficial performance when profiling and drilling carbon fiber composites. Those benefits include dramatic cooling of the cutting tool tip, which reduces wear and extends tool life. Most importantly, however, the tool will cut through the carbon fiber layers much better with fewer, if any, ragged edges. For drilling, instead of the large through holes used with flood coolant, the holes for CO2 are much smaller, in the 150 to 300 µm range. These tiny holes not only cool the drill but also the material, so the drill makes clean entries and exits. Both internal and external type CO2 toolholders ensure drills cut through the last layer, as opposed to punching through it and leaving ragged edges. High tool usage rates provide the first indication that a shop may not be using the right toolholding. Regardless of workpiece material or geometry, a shop that runs through many instances of the same tool for one part needs a better toolholder, especially one that is high precision, makes for fast and easy tool changeovers, provides extreme gripping force and, most importantly, delivers near-zero TIR.powRgrip achieves near-zero TIR toolholding Out-of-balance, poorly manufactured toolholders generate vibration that increases exponentially from the toolholder to the cutting tool tip. So, the longer the cutting tool, the higher the levels of runout. While the complete elimination of TIR and vibration is impossible, the REGO-FIX powRgrip toolholding system reduces both to near-zero levels. The powRgrip system consists of three basic components – holders, collets and press-fit assembly mounting units. In manual or automatic configurations, the hydraulic press-fit assembly units quickly press collets into holders with up to nine tons of force. The collets have high-precision tapers that match with equally high-precision internal tapers in the holders, all of which creates the system’s extreme levels of transferable torque. Unlike other clamping systems where heat or hydraulics are used, the powRgrip system uses the mechanical properties of the holder material to generate its tremendous gripping force. Such taper-to-taper collet-holding systems deliver extremely high levels of precision, and as a whole their TIR is typically less than 3µm, which ensures accurate finished parts. Such precision optimizes the machining of complex, critical Aerospace and Defense industry components through the use of high speed cutting (HSC) or high performance cutting (HPC) strategies. The lower the TIR, the less tool vibration, and the less vibration, the longer cutting tools last, which in turn reduces overall tooling costs.

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ENGINEERING TECH

FEV Expands Development Capabilities with Launch of FEV.io Intelligent Mobility Software Brand

FEV North America | April 25, 2022

FEV Group is combining its long-standing expertise in intelligent mobility and software development with the establishment of their new FEV.io brand. This move is intended to accelerate and optimize innovative power and interdisciplinary collaboration in the areas of automated and autonomous driving, as well as connectivity of infrastructure, people, and vehicles. The result will be powerful new solutions for intelligent, safe and sustainable mobility. Tomorrow's vehicles will be embedded in the digital lives of their users. Software-driven areas such as ADAS/ADS, infotainment and connected functions will be key differentiators in the user experience. "We have been supporting our customers in the successful development of intelligent mobility solutions for many years, and we see the FEV.io brand as a way to extend the value we provide in this space significantly, This ranges from design and industrialization to the provision of frameworks and tools." Professor Stefan Pischinger, President and CEO of FEV Group. Software upgrades and a constant flow of data between vehicles, infrastructure, people, and the cloud backend, have a significant impact on how modern vehicles are developed today due to their complexity. As such, they also directly impact customer needs and the pace of development. "Our methodologies in scenario and model-based systems engineering provide a unique benefit and help us to master even the most sophisticated system complexity," said Dr. Thomas Hülshorst, Group Vice President of Intelligent Mobility & Software at FEV. This approach allows the company to bridge the gap between the vehicle and ITC (information technology and communications) and deliver state-of-the-art connected solutions with an end-to-end view of the data pipelines from the vehicle to the backend. FEV.io's structure allows it to guarantee an agile and quickly adaptable working model for its customers around the world. Therefore FEV.io is globally presented as a brand in the local organizations and additionally established as an agile legal entity FEV.io GmbH close to the German FEV headquarters in Aachen. Should a customer also require support in energy and mobility system - or even complete vehicle - development, the newly founded brand will work closely with the FEV Group to offer all solutions "from a single source" at more than 40 locations worldwide. In addition, FEV.io will continuously strengthen its expertise with input from the consumer electronics, cloud, and automotive industries; and collaborate in the IT arena with market leaders such as Wipro. Intelligent mobility – FEV.io's range of services: Systems Engineering enables FEV.io to describe digital representations of real systems for its customers in a model-based manner. On this basis, dependencies are identified, and test scenarios are derived, enabling cost-efficient and fast product cycles. Functional Safety & Cyber Security is organized in accordance with all industry standards for connected, automated and electrified vehicles. FEV.io accompanies and leads customers through all development steps. Connected mobility will offer a unique user experience in the future. The provision and connection of vehicle data will help make mobility significantly safer and more convenient. FEV.io develops corresponding ecosystems where cross-domain competence is crucial. ADAS/ADS systems interact with all areas of the vehicle, such as steering, brakes, powertrain and infotainment. At the same time, they also interact with intelligent infrastructure and digital maps. FEV.io supports its customers in mastering this complexity. Infotainment: A seamless and holistic human-machine interface (HMI) is a key point of differentiation for vehicles today. Therefore, the development of cutting-edge display solutions and creative interaction technologies is one of the most important areas of innovation. These systems must enable convenient and effective communication between passengers and the vehicle while ensuring a safe vehicle. FEV.io verifies efficient development and integration into the entire vehicle. SW and EE platforms: Buyers are increasingly opting for a vehicle that is online, seamlessly connects to the user's digital world, and delivers a premium digital experience. To achieve this, hundreds of millions of lines of code, ECUs and electronic components need to be integrated into scalable platforms. This is where FEV.io provides high-quality and robust solutions through its cross-domain system expertise and global presence. SW and EE integration: Future vehicles will have extensive functions for assisted and automated driving, enabled by connectivity and a growing proportion of software and complex algorithms. Greater functionality means, above all, greater complexity and responsibility. Automotive software must be maintainable, updatable, and diagnosable in the context of SW and EE integration. FEV.io enables this while embedding it in a powerful, reliable E/E architecture. FEV.io provides its customers efficient solutions for intelligent, safe and sustainable mobility. Source: FEV Group About FEV FEV is a globally leading engineering and digital mobility company. Together with our customers, we are shaping the future of the mobility sector for sustainable, carbon-neutral and efficient, connected, and safe transportation. Through our in-depth expertise we provide customers and society with cutting-edge solutions for the highest value of mobility and most advanced transport experience from A to B. Our expertise includes intelligent software and sustainable propulsion system development, as well as full vehicle engineering. Additionally, our range of services includes sophisticated systems engineering, cyber physical system development, software- and E/E-integration for software defined vehicles with highly automated and safe driving functionalities as well as vehicle integration. FEV's engineering capabilities span the entire mobility ecosystem including all on-road applications as well as rail, marine, aerospace, agriculture, construction, mining, and industrial applications. Additionally, we transfer our elaborate know-how and innovations to adjacent markets, such as the energy sector, to deliver best-in-class industry solutions.

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ENGINEERING TECH

Saulsbury Awarded EPC Contract for Two Cryogenic Processing Facilities in West Texas

Saulsbury | January 18, 2022

Saulsbury was recently awarded the EPC contract for the design and installation of two cryogenic processing facilities in the Midland Basin. The facilities, designed with a base-rated capacity of 200 MMSCFD each, mark Saulsbury's 61st and 62nd cryogenic processing facility projects since 2006, representing nearly 11 BCFD of processing capacity, and its 23rd and 24th cryogenic processing facility in the West Texas region. Saulsbury will be responsible for the engineering, procurement, and construction of the processing facilities that will include amine treating, molecular sieve dehydration, cryogenic gas processing, residue gas compression, nitrogen rejection, slug catching, condensate stabilization, and all balance of plant equipment, utilities, electrical, instrumentation, and controls infrastructure. Work on this facility started in December with a phased commissioning starting in late 2022. "This important project will continue to showcase Saulsbury's position as a premier EPC contractor for delivering high-quality, speed-to-market solutions for the midstream gas processing space,Our continued practice of implementing project-specific design innovations and optimization will further strengthen our commitment to delivering one of the Midland Basin's premier facilities for our client." -Sean Trotter, Saulsbury VP EPC Engineering/Major Projects. For Saulsbury, this award further solidifies the company's reputation and longstanding history as an industry leader in the oil and gas industry for self-performing the full engineering and construction of cryogenic gas processing facilities. Saulsbury is well known in this industry for its successful project execution and world-class safety performance. About Saulsbury Industries Saulsbury Industries is a full-service engineering, procurement, fabrication, and construction company that specializes in building the infrastructure necessary to fuel the future. Saulsbury serves its clients in heavy industrial markets by designing and building safe, well executed, capital-efficient projects nationwide. Headquartered in Odessa, Texas, the company's national office footprint includes Dallas, Houston, Port Arthur, Henderson, Abilene, Pecos, and Corpus Christi, TX; Carlsbad, NM; Tulsa, OK; and Bismarck, ND. For more information, please visit www.saulsbury.com and follow Saulsbury on LinkedIn, Facebook or Twitter.

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MATERIALS

LandSouth Continues Long-Time Partnership with Developer by Breaking Ground on Presidium Park

LandSouth | December 22, 2021

LandSouth Construction, a Jacksonville, Fla.-based, award-winning general contractor, broke ground for the construction of Presidium Park, an upscale multifamily community in Jacksonville, Florida. The developer for Presidium Park, Presidium, continues a long-time relationship between the two groups. The four-building complex will be located at 8181 AC Skinner Parkway in Jacksonville and is scheduled to be completed late 2023. "It's great to continue our partnership with Presidium and we're excited to offer a beautiful, new development to the growing Jacksonville area,LandSouth and Presidium have come together several times to bring amazing multifamily communities to life. Presidium Park is the next to showcase both organizations' commitment to innovation and excellence." -LandSouth President and CEO, James Pyle. Louis Fegan is the LandSouth project manager for Presidium Park and Brad Chilton is the superintendent, continuing their successful partnership. Dwell Design Studio is the architecture firm for the development. Presidium Park will be a 4-building, midrise, 5-story development featuring 33 different types of units. Future residents will have the choice of floor plans that range from 616 square feet to more than 1,703 square feet, both single and multi-bedroom. Presidium Park will offer residents a clubhouse, two-story amenity center, swimming pool with pavilion, car spa, and several high-end amenities. Presidium Park boasts proximity to area entertainment and restaurants, including St. Johns Town Center. In addition, Presidium Park is close to the University of North Florida. "Jacksonville continues to grow at a remarkable rate and Presidium Park will provide more luxury housing for the people of Jacksonville,Presidium and LandSouth have a long history of bringing best-in-class communities to life and I'm thrilled to lead the way on Presidium Park." -Louis Fegan, the LandSouth Project Manager. LandSouth will employ its unique integrated construction approach to build Presidium Park. Service components work together to provide a seamless delivery system through proven procedures, systems, and technology. ABOUT LANDSOUTH CONSTRUCTION LandSouth Construction, the Southeast's premier general contractor, specializing in multifamily, senior living, and mixed–use development, was named one of Engineering News Record's Top 400. Since 1998 LandSouth has transformed ideas into best–in–class communities. Headquartered in Jacksonville, Fla. LandSouth has completed more than 25,000 multifamily units. For more information, call LandSouth Marketing Manager, Erica Zumstein, (904) 273-3182, Ext. 109 or visit www.landsouth.com. ABOUT PRESIDIUM Founded in 2003, Presidium is a fully integrated real estate firm with an 18-year operating history and an existing portfolio totaling over $2 billion AUM. Presidium is committed to providing best-in-class housing for individuals of all income levels and creating great spaces that enhance people's lives. For more information about Presidium, visit www.presidiumre.com.

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Spotlight

Machine learning is becoming increasingly popular with TDWI audiences. In recent surveys, we’ve seen the use of this technology (and its related technology: statistics for predictive analytics) in the early mainstream phase of adoption. Machine learning is being deployed in a wide range of use cases.

Resources