As nominations close for the 10th Endeavour Awards, we highlight the finalists for each category, giving you an insight into innovation and excellence in the manufacturing industry.
Profile Cutting Systems
Profile Cutting Systems has been nominated for the Australian Steel Innovation award for the development of an Australian first profile cutter made entirely from Australian steel. The company's 7500 BHP is essentially a very large profile cutting machine with a large drill on it.
Profile Cutting Systems explained that on traditional plasma cutters such as X-Y CNC machines are able to cut steel plates, this latest development is the next level in cutting as it is basically an entire machining centre on ensconced on a single machine, so instead of only being able to cut a hole you can actually now cut and drill a hole for a perfect hole.
This overcomes many of the problems facing large end fabricators such as BHP, where they are specifying that whatever holes they need made have to drilled not cut, as cutting causes a slight taper which can causes shearing on bolt holes down the line. On top of this you can drill a hole faster than you can cut it, so you aren't losing any production time.
PCS added that the plasma can also bevel as well, so you can cut on angle to provide 3d cutting. While machines there are several manufacturers of these types of equipment and profile cutting machines being imported, it is first time that it has been fabricated and manufactured in Australia. PCS added that other makes and models been made in oz, but not in same league as this, as it is more powerful.
The machining centre has 60 hp main spindle on it, can provide oxy fuel cuts, drill and also has a 24 tool carousel on it, as well as a large range of drill sizes. Built entirely from Australian steel, the machine has been on the market for almost a year, 10 months at this stage. Response has been very strong and we are already making fourth machine at the moment.
Profile Cutting Systems will be exhibiting the machine at NMW, in May.
Modular Wall Systems
Australian security, boundary, and acoustic wall manufacturer Modular Wall Systems has been nominated for Australian Steel Innovation for the development of Quikwall, the world's first moveable, height extendable temporary walling solution. Modular Wall Systems purchases all steel required for manufacture from OneSteel and BlueScope Australia.
QuikWall's innovative integration of a winch system with the wall design allows for the extension in height that characterises QuikWall. QuikWall components are manufactured out of Australian steel. They are designed, laser cut and tested to precise standards.
Used by Australia's leading mining and construction companies, QuikWall represents Modular Wall System's innovative and creative spirit and ability to respond to an identified customer need. Through extensive research and development and in consultation with major mining companies, Modular Wall Systems developed the first free standing, relocatable, lightweight and height adjustable temporary noise wall in the world: QuikWall.
The wall's height can be extended and lowered, offering the ultimate flexible solution to deal with all climatic conditions (a fixed height, 4 meter high wall for example, might get damaged or blown over in high wind regions). Quikwall's height would simply be lowered if conditions so dictate.
Using the innovative winch assembly, QuikWall can easily be extended from a resting height of 2.6 meter to its maximum 4.4 meter height in less than a minute. The patented design of this product allows for compact
Transportation in large volumes and swift modular installation, mitigating large site mobilisation and establishment costs.
T.W. Woods innovative Australian made coal chutes have been recognised for the Australian Steel Innovation award. The chutes are smooth flowing low-height transfer chute are built to overcome space, spillage and conveyor bulking problems common in coal mining and coal handling facilities.
All of the material used in production of the chutes is Australian. The chromium carbide material used in construction is either a Bradken Product (Duaplate) or the Arcoplate is made by Alloysteels. Both are manufactured in Western Australia. The design has already been proven service with some of Australia's leading coal producers.
A bonus of the design also is that it has been quality engineered in T.W. Woods' own extensive metal working facilities to easily outlast conventional designs and far exceed typical warranties. The design enhances cost-efficiencies in the production of coal, of which Australia produces more than 500 million tons a year and is the world's largest exporter by proportion of production. Exports alone earn more than $50 billion a year.
The company's low-height transfer chute features a conical head developed by mining specialist designers to maintain high volume high flow rates when conveyors change direction either underground or on the surface.
The design more than covers what we do. It's a robust simple design that's pretty wear resistant and easy to adjust for our operations, which involve about 1200 tons and hour with throughput containing lumps up to 300-400mm, the company said.
T.W. Woods' tough hardened steel design - built to easily outlast conventional types and incorporating large quantities of Australian steel - is based on the group's experience of more than 40 years in constructing plant for mining, energy, construction and materials handling plant throughout Australia.
Metso has been nominated for the Australian Steel Innovation Award for the creation of massive train unloaders using Australian steel. The unloaders, which are used by Fotescue Metals Group and Rio Tinto subsidiary Hammersely Iron to unload its ore trains at Cape Lambert and Port Hedland, were initially installed in 2010. Since that time the miner has installed two more unloaders, the latest in 2012.
Already recognised by the Australian Steel Institute, winning the Engineering Projects Steel Design Award, the single tandem car dumpers were built in conjunction with CIMVEC, in Henderson Western Australia. The cars weigh in excess of 350 tonnes and are designed to off-load two train wagons per operation. The project involves around 400 tonnes of Australian AS/NZS 3678/9 Grade 250-300 steel plate ranging from 8mm through to 250mm thickness.
Due to the high fatigue cycle of the structure Metso specified welding to the Australia standard code AS1554 part 5 code for high fatigue structures. Special welding techniques were developed to cater for the design's specifications, which required the welders to pass specific welding qualification tests to even work on the project.
A large purpose-built gas fired furnace was erected on site by CIMVEC to carry out post-weld heat treatment of the completed structure prior to machining.
Creation of the rail car unloaders took around nine months to complete and used more than 12 tonnes of welding consumables.