< PreviousI t’s expected that the global production capacity for electric-vehicle (EV) batteries will need to more than triple from 2020 to 2025 to meet the world’s estimated EV produc- tion target. If you help run one of the many EV battery megafactories or ‘gigafactories’ that are in operation today, or you’re helping launch one of the more than 100 gigafactories that are planned to be built, you may feel confi dent that this goal will be met. But it’s important to remember that deliver- ing the billions of watts of energy that EVs will need in the coming decades will require more than scaling up traditional production tech- niques and technologies a massive amount. It will require new ways of thinking about pro- duction processes to maximize speed, fl exibil- ity and throughput. To that end, here are two capabilities that should be considered in every gigafactory: INTELLIGENCE CONVEYANCE SYSTEMS Keeping up with growing EV demands while also accommodating changes to EV battery technology will require high-performance, fl exible machines. Equipment like traditional conveyance sys- tems may only slow you down. These systems use motion-control technologies with hun- dreds of mechanical details, like rotary-driven chains, belts and gear boxes. As a result, the systems have limited fl exibility as well as op- erational speeds and acceleration/deceleration speeds that may fall short of your gigafactory’s needs. A better alternative is a motion-control sys- tem with independent cart technology. Free from the constraints of a traditional convey- ance system, this system can: • Create faster, more fl exible battery lines using independent, programmable movers. • Dramatically reduce changeover times with simple software profi les that allow you to change products at the push of a button. • Reduce downtime because they have fewer moving parts. In one case, Eagle Technologies used this technology on a battery pack assembly ma- chine it developed to help maximize EV battery throughput. The machine’s capabilities span from indi- vidual cell sorting to full battery module and pack assembly, while also performing required testing. The machine incorporates linear servo motors that position loads in precisely the cor- rect direction at high speeds. And changeovers simply involve selecting the correct mode from the operator interface. A DIGITAL THREAD What is a digital thread? It’s a continuous fl ow of information that turns insights into actions and connects previously siloed business func- tions, improving their ability to work together. A digital thread can help you do that. With MES software, for instance, you can integrate your control and business systems to execute and track orders across your enterprise. You can also gain the additional context you need to turn production data into actionable infor- mation. You can even start small with MES applications that address your specifi c manu- facturing challenges. Want to get a handle on defects? Use an MES quality application to track, identify and alert when either a machine’s or operator’s processes go outside of their prescribed limits. Or you can use a track-and-trace application to gain complete traceability of batteries through the manufacturing process and help make sure that batteries are safe for use. Eventually, you can scale up the applications to an enterprise MES software that gives you one version of truth across your operations. Other innovations can help you ease access to digital thread insights. Smart objects, for example, build into the control automation layer the capability to capture the OT context of data throughout the digital thread. The con- textual data is packaged into a confi gurable information model, which can then be eas- ily consumed by upstream IT applications to uncover higher-value industrial performance insights. By John Miles, business development manager, Rockwell Automation HOW BATTERY MAKERS CAN PREPARE THEIR PRODUCTION OPERATIONS TO MEET THE DEMANDS OF THE FAST-GROWING EV INDUSTRY COMMENT 10 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021masaoodpower.com 24/7 Service Hotline: 800 68823 MICROGRID & HYBRID SOLUTIONS Microgrid solutions help sustain the future of energy and ensure reliable power supplies to meet customer demands.T he competition to electrify vehicles is not simply the competition between rival manufacturers. What is now at stake is a competition between two rival, diametrically opposed manufacturing methods. While many persist with the mantra of bigger is better, oth- ers are heading in the opposite direction. The traditional assembly line has dominat- ed manufacturing for decades. So too has the idea that bigger is better. Economies of scale can be achieved through larger and larger pro- duction facilities. That way of thinking lies behind the emer- gence of gigafactories – enormous manufac- turing facilities that can produce the batteries and vehicles that will move humanity toward greener transportation. The phrase gigafactory was fi rst used by Tesla CEO Elon Musk in 2013. Situated in the Nevada desert, Tesla expects its original giga- factory to be the largest building in the world once completed. However, six years after the beginning of construction, the plant is still only 30 percent complete. Is there an alternative to the traditional as- sembly method of production and economies of scale through ever increasing manufacturing footprints? For advocates of the microfactory concept, the answer is a resounding yes. INTRODUCING THE MICROFACTORY The phrase microfactory was coined in 1990 by the Mechanical Engineering Laboratory of Japan. It captures the idea of a smaller manufac- turing footprint, employing cell-based manu- facturing and higher levels of automation, to de- liver more innovative and customisable designs. A major champion of this approach has been the Phoenix-based company Local Motors, which produced the world’s fi rst 3D-printed car in 2014. More recently, it is British start-up Ar- rival that is spearheading the concept. Having recently emerged from stealth mode, the com- pany listed on the New York stock exchange for a whopping $5.4 billion. Arrival is focusing on buses and commercial vehicles. It has secured investment from Honda, Kia and UPS. The latter has a standing order for 10,000 electric vans, which will be manufac- tured at Arrival’s fi rst microfactory in Banbury, Oxfordshire. A second microfactory in South Carolina will focus on buses. These manufacturing facilities are a stark contrast to the colossal structures that many of the world’s leading vehicle manufacturers are investing in. While Tesla’s Nevada gigafactory already boasts a footprint of 1.9 million square feet with over 5.3 million square feet of opera- tional space across multiple fl oors, an Arrival microfactory can be deployed into a standard 200,000 square foot warehouse. SIZING UP THE COMPETITION The bold contention behind this approach is that the microfactory will allow Arrival to produce electric commercial vehicles at a price point that is competitive with ICEs. The start- ing point for this argument is the lower capital costs required for the microfactory. As a gigafactory is both enormous and pur- pose-built, it takes many years and signifi cant capital expenditure. The microfactory takes just six months to be up and running and it can be established in a generic warehouse. Through using their own proprietary com- posite material, Arrival has also removed the need for painting and stamping – both activi- ties which traditionally occupy signifi cant fac- tory fl oorspace. Finally, advocates of microfactories promise to deliver signifi cant savings in outbound lo- gistics. Rather than having one central factory, having hundreds of smaller factories deployed in proximity to the markets they are providing for means the product is closer to the customer. While this all sounds good in theory, it is yet to be demonstrated in practice. The proof will be in the pudding, as the saying goes. One major challenge will be inbound logis- tics. Having more factories means shipping components and materials to more locations. That is one reason why the company is heavily focused on vertical integration – Arrival has its own chassis, powertrain, body and electronic controls. For its commercial vehicle, 60 percent of the parts are vertically integrated, according to chief of procurement, Tracey Yi. While that fi gure might be high, it still leaves 40 percent of the vehicle parts to be de- livered by parts suppliers. If those parts need to reach factories located in dozens or perhaps hundreds of locations, then you risk any sav- ings on outbound logistics being cancelled out. In any case, even if 100 percent vertical inte- gration could be achieved, you are still having to move components and materials to multiple locations for assembly. FLEXIBILITY THROUGH A SMALL- ER FOOTPRINT The cell-based manufacturing of the microfac- tory is geared toward fl exibility and innovation. Each cell is a cluster of robotic arms, with the manufactured product moving its way from one By Roger Brereton, head of sales, Pailton Engineering IS ‘GIGA’ ALWAYS BETTER IN THE EVOLVING LANDSCAPE OF EV MANUFACTURING? COMMENT 12 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021cell to another via an automated robotic vehicle. Arrival is employing standard robots but build- ing its own sophisticated software to improve this process. In a traditional assembly line, the produc- tion process is linear. In the microfactory, the product can visit the diff erent cells in any or- der, perhaps even returning to the same cell. If a new cell needs to be added for greater cus- tomisation, this is possible without halting or disrupting production. It is no coincidence that Arrival has chosen to focus on commercial vehicles and buses, where the need for design fl exibility is greater given the diff erent demands placed on these vehicles. The company has recognised that for these sectors, a one-size-fi ts-all approach is less eff ective and is positioning itself accordingly. We are reaching a critical point in the road toward vehicle electrifi cation. What is making this story so fascinating is that the key original equipment manufacturers (OEMs) in this un- folding narrative are placing their bets on dia- metrically opposing approaches to manufactur- ing. There are some bold bets being placed and it is probably too soon to call the likely winners in this race. From humanity’s point of view, it can only be a good thing that we haven’t put all our eggs in one basket. Our Capabilities include: • Quality as per VDA, ISO 22241- 1 to 4 and ISO 9001 - 2015 • National distribution network • 10 L & 20 L Can, 1000 L IBC and Bulk Trychem FZCO PO Box 263945, Dubai, UAE Email: info@trychem.com For more information, please CALL +971 4 880 7059 CERTIFICATION: • ISO 9001 - 2015 As a premier supplier of Quality AdBlue®, Trychem provides a safe and environmentally friendly solution for SCR technology www.trychem.com YOUR ADBLUE ® TOTAL PACKAGE PROVIDER COMMENT 13 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021O n the road to making the heavy in- dustries carbon-neutral, our biggest hurdle is not the technical challenge, but the need to let go of “the way we’ve always done it”. I believe embracing change, taking risks and becoming truly entrepreneurial in our approach is the route to creating a low carbon future. Over the last couple of years there have been increasing calls for the world to switch to more sustainable economic models and practices. However, there is a big gap between this demand and what is currently practically possible. According to the United Nations’ annual ‘emissions gap’ report, global temperatures are on pace to rise as much as 3.2 degrees by the end of the century. This is signifi cantly higher than the two degrees many countries have pledged to stay ‘well below’. Yet, in the fi ve years since the Paris Agreement, carbon emissions have continued to rise. Organizations such as the World Economic Forum and the development banks are urging governments to support the post-coronavirus economy by investing in infrastructure proj- ects that are sustainable, through ‘green stim- ulus packages’. There has been much specula- tion that this is our big chance to re-launch economies on a more sustainable footing. However, there are many practical hurdles to overcome in satisfying an energy-hungry planet with limited resources. The kind of massive infrastructure change required to meet the Paris targets does not happen quick- ly and the reality is we will need to continue to satisfy the demand for power as we transi- tion to low carbon solutions. To navigate this transitional period many of the world’s leading energy companies are setting out their plans for the future. Recent legal and shareholder actions are adding extra pressure to this process by demanding that the energy sector sets out more ambitious low carbon strategies and roadmaps. The good news is we are not starting from scratch: there is much knowledge and expe- rience that can be ‘reused and recycled’ for more sustainable applications. In this way, Mammoet’s expertise from the traditional heavy industries can help our customers to meet their strategic sustainability targets and to create a whole new “greener” infrastruc- ture. For example, the experience we have built up in load-outs and heavy lifting off shore can be utilized for the effi cient execution of wind projects - particularly fl oating wind, where foundations will reach over ten thousand tonnes. Modularization techniques - used to deliver more effi cient construction for con- ventional industrial projects over the last three or four decades - will also enable the renewables sector to enjoy faster, safer and more cost-eff ective projects with potentially lower carbon footprints. The wind industry can particularly benefi t from expertise from conventional industry. As hub heights increase and wind turbine By Erica Gray, head of sustainability, Mammoet MOVING TOWARDS A LOW CARBON FUTURE FOR THE HEAVY INDUSTRIES IS A HUGELY CHALLENGING ENDEAVOUR. THE GOOD NEWS IS WE ARE NOT STARTING FROM SCRATCH components grow ever-larger, technologies developed with diff erent industries in mind will make a big diff erence. Super heavy lift cranes will help to broaden participation in wind energy by making more ports viable for off shore wind projects, while on land they will allow assembly of huge turbine structures and support the provision of the necessary in- frastructure for power distribution networks. And it doesn’t end there. New facilities such as waste-to-energy plants, biofuel facili- ties or co-located steel and energy production plants can all benefi t from highly effi cient modularization techniques, supported by the heavy lifting know-how and equipment that have moved modules of over 40,000t. Besides new construction, there are also COMMENT 14 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021opportunities for existing facilities to up- grade to more effi cient techniques or to in- clude carbon capture. The extensive experi- ence our colleagues have accumulated on how to work in active, busy and constricted plants can be a huge benefi t here – not to mention the highly-specialized gantries and cranes that have been developed for this purpose. In addition to enabling new infrastructure through more effi cient solutions, heavy lift- ing and transport companies can help EPCs and owners to bring down the impact of their own operations by switching to low carbon equipment. Cranes and transport solutions that are hybrid or electrically powered, such as the electric SPMT or more effi cient systems such as our Trailer Power Assist, can help bring more sustainable infrastructure online while reducing a project’s carbon impact. This is of growing importance in the civil sector, where carbon emissions are closely monitored in line with governmental requirements to re- duce the carbon footprint of publicly-funded projects. Working with low carbon fuels, such as biofuels or fuels derived from waste prod- ucts, can reduce carbon emissions further. We have already completed our fi rst project using fuel derived from waste cooking oil. Even preparing the ground on which you work can be done in a way that is less carbon emitting, through the use of products such as Enviro-Mat. There are many ways in which Mammoet can enable the energy transition, especially by using our expertise from elsewhere in heavy industry to support the growth of re- newable energy and help our customers de- carbonize existing ways of working. There is so much more to be discovered if we are will- ing to embrace the new and take the bold step away from the old. By working with us early in project plan- ning we can fi nd ways to cut the carbon im- pacts of projects. We are open to new ways of working and combining expertise and per- spectives to support the energy and heavy in- dustries in becoming a big part of the solution to the climate crisis. Mammoet recently executed its fi rst operation using low-carbon HVO fuel. COMMENT 15 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021T he world is moving toward a more en- vironmentally conscious, sustainable future, and that includes the construc- tion industry. As more emissions incentives and zero-emissions levels are set for on-road vehicle improvements, the off -road industry is following suit. While environmental requirements are more common in Europe, they’re starting to gain ground in North America. More and more local and state/provincial governments are adopting clean air policies, so if contrac- tors want to win these bids, they need to prove that they’re working with equipment with re- duced or zero emissions. Also, some jobsites simply require reduced or zero emissions — indoor construction jobs are a great example. Ventilation poses a prob- lem as diesel-powered equipment emits ex- haust fumes. Indoor projects can now benefi t from the low noise and zero emissions electric machines off er. For most contractors who consider the move to electric machines, the biggest chal- lenge is simply a change in mindset for elec- tric equipment. Customers must have an adequate charging infrastructure in place to ensure machines operate as planned. While a 110-volt set up will charge the units over time, a 240-volt setup is necessary to charge the machines quickly. And for remote jobsites, a solar array may be necessary to provide power when an electric grid isn’t an option. PERFORMANCE AND PRICE Power and performance are what make elec- tric machines such great options. For exam- ple, the Volvo ECR25 electric excavator has the exact same digging depth, dump height, break out and tear out forces, and dimen- sions as its diesel equivalent. The L25 Electric wheel loader has a few slight diff erences from the diesel version, but nearly all of those are in the electric machine’s favour. Customers will get the performance they expect from these machines. With diesel construction equipment, oper- ating time is defi ned by the engine run hours, By Lars Arnold, electromobility product manager – North America, Volvo Construction Equipment WHAT’S DRIVING ELECTROMOBILITY IN CONSTRUCTION? COMMENT 16 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021and a lot of those hours are counted while the machine is at idle. With electric machines, as soon as the operator stops working (for example, a landscaper waiting for pipe to be placed in a trench he’s just dug), the electric motors turn off within a short time period. During this time, no operating hours are be- ing accumulated. So over time, jobs can rack up 10,000 hours on a diesel machine where they might only add 6,000 or 7,000 hours to a comparable electric machine. Many of the early adopters aren’t con- cerned with the cost to be one of the fi rst to use electric machines to explore new business opportunities. For many, they’re looking to potentially make the switch over time so their equipment better aligns with their core values — care for the environment, as an example. Currently, the cost of electric machines is higher compared with diesel-powered ma- chines, but there are also signifi cant savings to consider in regard to maintenance. That will change as more contractors come on board and make electric machines more com- monplace in the construction market — ROI is expected to follow the anticipated trend in the electric automobile market. But as we’ve already discussed, electric machines will accumulate fewer hours than diesel machines, there are no costs associated with engine maintenance, and they could help contractors as sustainability require- ments start being incorporated into RFPs. It’s about more than just purchase price. FAST MACHINE CHARGING In addition to solar arrays and other sustainable methods to maintain a power grid for remote charging, apps will also be devel- oped that show operators the state of charge (SOC) of their machine. From a mobile phone, both owners and operators could check the machine’s location and the SOC, and fl eet managers will have the ability to monitor ma- chines remotely to ensure daily productivity goals are met. As we explore new solutions for machine charging, one potential concept is to have a DC rapid charger, which would charge the machine within a very short period of time. The ECR25 Electric, for example, could be charged within an hour’s time from 0% to 80%; and the L25 Electric, within two hours’ time from 0% to 80%. This is possible because the charging of the battery is linear up to roughly around 80%, then it fl attens out and slows down before the full charge is reached to preserve the battery. These are the same charging characteristics as any lithium-ion battery product, such as cell phones or cordless power tools. Lars Arnold, electromobility product manager – North America, Volvo Construction Equipment. COMMENT 17 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021T here are several factors to consider while selecting mobile power equipment for construction and oil and gas applications. Mobile generators are vital to construction activity, and therefore, the quality of the machines should be the priority along with the right generator sizing, physical size and ease of transportation. Akram Tamari, regional general manager, Atlas Copco Rental Middle East & India, says: “The selection of mobile generators should be done on a case-by-case basis depending on the required wattage. Operating costs should dominate the decision-making process. Fuel could easily constitutes 85% of the total rental cost, and it could be tricky to manage the fuel consumption of rental machines. Here’s where Atlas Copco machines stand out with their unique fuel effi ciency features.” All these criteria apply to oil and gas projects as well, but they also need to fulfi l additional demands such as enhanced safety features, control systems, and redundancy. As oil and gas contractors demand environment friendly power generation solutions in line with their sustainability goals, fuel consumption has become another crucial factor. This has created a need for more power saving, redundant systems. Atlas Copco has several ongoing off - shore and on-shore projects that require temporary power generation. The company’s rental division has supplied the Atlas Copco TwinPower (1.5 MW) generator to an international oil and gas contractor for one year to operate remotely operated vehicles (ROVs), which are being used extensively for drilling and subsea construction support in deep-water exploration and development projects worldwide. Akram elaborates on Atlas Copco’s recent product development milestones in response 18 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021 RENTAL EQUIPMENT ATLAS COPCO BRINGS MORE CHOICE TO THE MOBILE GENERATOR MARKETto changing customer requirements. “Atlas Copco is committed to continual product development and innovation. We off er versatile, robust and compact generators that are engineered and tested to deliver the highest levels of performance, and reliability. To improve the stability of our generators, for example, we have equipped them with a permanent magnet generator (PMG) excitation system which provides high short- circuit capability of 300% rated current for 5–10 seconds,” says Akram. Atlas Copco is the fi rst global generator manufacturer to address market needs for modular energy storage. The Atlas Copco ZenergiZe range of battery energy storage systems can be used as a standalone solution or combined with generators to create a hybrid power solution. “By using high-density lithium-ion batteries, these systems are able to achieve zero CO2 emissions, zero noise, and have virtually zero maintenance needs, thus enabling operators to minimize environmental impact while benefi ting from a low cost of ownership,” he says. Atlas Copco has also introduced tools to help customers choose the right power generators for their needs. For example, Atlas Copco’s ‘Light The Power’ mobile app is a power and light calculator to help users with diff erent technical requirements to choose the best Atlas Copco solution for their needs. It includes generators and light towers sizing, simulation of modular power plants, cables sizing and estimation of noise levels. With increase in awareness about carbon neutrality and demand for alternative energy, Atlas Copco is introducing hydrogen-powered generators to its fl eet. “In power generation, the hydrogen fuel cell is one of the leading options for storing renewable energy. Fuel cells have the potential to replace the internal-combustion engine in vehicles and provide power in stationary and portable power applications because they are energy-effi cient, clean, and fuel-fl exible. Green hydrogen is one of the hottest topics of discussion in the energy industry. In the Middle East, we have seen several promising political decisions regarding the intended acceleration of major nations towards a carbon-free energy reality,” says Akram. “We focus on delivering the technology and services that can enable our customers to focus entirely on their core businesses. That’s why customers prefer Atlas Copco machines for their reliability, quiet operation, easy of transportation and installation, fuel effi ciency and low total cost of ownership,” he adds. Akram Tamari, regional general manager, Atlas Copco Rental Middle East & India. 19 PLANT / MACHINERY / VEHICLESwww.plantmachineryvehicles.comOCTOBER 2021 RENTAL EQUIPMENTNext >