Modern Moats

Herstmonceux Castle and Moat for TO6410 cc Dave Croker

Herstmonceux Castle and Moat for TO6410 cc Dave Croker


Planners who were trying to safeguard valuables back in the middle ages discovered that it takes more than fortifications to succeed. This is especially true when the fortifications have secret doors that were installed by the builder. I suspect that the fortress defenders discovered that the addition of a moat also flooded the tunnels under the walls. In this digital age, the task of defending a company’s digital fortress is daunting. The magnitude of this task will only increase as more of our foreign-built devices become internet connected.
by Stan Schneider Real Time Devices

by Stan Schneider Real Time Devices


As revelations by Edward Snowden and others have demonstrated, the fortress walls of these IoT (Internet of Things) devices come with pre-installed secret doors. This fact has not escaped the thieves that exploit these weaknesses. In much the same way that Google crawls the web looking for home pages, a search engine named Shodan crawls the web looking for the hidden back doors http://www.forbes.com/sites/kashmirhill/2013/09/04/shodan-terrifying-search-engine/. Using this search engine to help them, I am not surprised that the thieves find that some of these doors are unlocked. So how do you go about installing a moat before the thieves make off with the crown jewels? What does a modern moat look like? The first moat of the electrical age was related to the high voltage wires needed to transmit power for long distance. Nickolai Tesla working for George Westinghouse developed the high voltage power system we use today. Glass insulators kept the high voltage from shorting to ground.
Sophisticated insulators stop the loss of high voltage power

Sophisticated insulators stop the loss of high voltage power

It is very exciting when the salt we use on the road causes massive fires in the substations melting the conductors. Obviously the fuses blow, but most of us have also lost a TV, radio or computer because the high voltage finds its way into our electronics. The fragile electronics in our computer chips died regularly, until we discovered how to use light in the form of opto isolators to build a non-conducting moat around the processor.
light waves protect microprocessors from voltage spikes  by Inductiveload

light waves protect microprocessors from voltage spikes by Inductiveload


Light can also be used to protect the program running the computer from hacking and malware. Early in the development of microelectronics a type of memory called UVprom was invented. Bright ultraviolet light bathed on the chip erases the memory.
Ultraviolet light erases this chip CC by SA 2.5  ST Microelectronics M27C2568-12FI

Ultraviolet light erases this chip CC by SA 2.5 ST Microelectronics M27C2568-12FI

The convenience of the electrically erasable chip has led to its wider use. In general, it is not convenient if spyware and malware are remotely added using the electrically erasable chip to steal the crown jewels. I suspect that the vandals of the middle ages would have liked conducting their raids without ever having to leave home. I believe that we will go back to locking in the operating program. It is promising to hear that Google is unveiling their Vault micro SIM card for a mobile phones. We will all be watching to see whether it actually improves security or is just to keep out every one but Google (and the NSA by hidden deal) http://www.cnet.com/news/googles-project-vault-is-a-security-chip-disguised-as-an-micro-sd-card/ This is probably why so many users cling to Windows XP (also named Windows NT) Daily web updates to fix the bugs in incomplete operating systems are a big gap in the moat we are trying to build around our data fortress.
In the early days of computing, many of us used time sharing. The derivative virtual machine adds one more level of security but it does not protect against back doors that were embedded in the parent operating system.
Virtual Marble Machine  CC by Torley

Virtual Marble Machine CC by Torley

I like playing video games, but if I am interested in data security I will go back to build and maintaining the moat. Windows NT is very stable and bug free operating system if is isolated from the web. Thinking in military terms it is better to have a mine field between you and the theives. We have all played minesweeper.
Memory with embedded "mines" can be built into the cables that connect to the internet

Memory with embedded “mines” can be built into the cables that connect to the internet

Remote probing is a lot more difficult if only a small amount of data is availaible at one time in a two directional buffer memory and random memory addressed are mined.
Currently 40% of the cost of new vehicles is software. Companies who wish to remain in business must take building a moat against the “Great Cannon of China” more seriously

Robot Vision

Vision - The holy grail of robotics

Vision – The holy grail of robotics


We would like to have robots perform the tasks that we as humans do not want to do. Many of these fall into the heavy, dangerous, repetitive, precise, finicky categories. As humans we learned to accomplish these types of actions as little children, so we do not have a step by step roadmap on how to get this type of task done
The blind leading the blind By UR INC Motoman SDA10 at Smith Springs Lab

The blind leading the blind
By UR INC Motoman SDA10 at Smith Springs Lab


Most of us who have implemented robots find that blind repetition of actions, however well conceived leads to less than desired results. Real processes are not perfectly consistent and real parts have tolerances. As engineers we normally try to compensate for the fliers that we have experienced, but new types of defects emerge in the global race to the bottom. For example it was only recently that I had to fight with bolts where the hex head was partially formed. This totally jams the automatic feeding and installation equipment. Dumb and happy. The robotic automation cannot cull out the defective parts which is a simple task for the humans that they replaced. Fortunately in this case, I included a proximity switch in my arm end that could be used for sorting.
Capacitive proximity switches detect objects before they are hit

Capacitive proximity switches detect objects before they are hit


It is possible to use a proximity switch to measure to an accuracy down to .001 inch. (high accuracy measurements have a significant time penalty due to multiple probe motions) I recommend including extra vision catagory features when implementing new robot installations. In this fast changing business environment it is highly likely that your robots will need to be taught new tricks before they are taken out of service. Small investments in sensors like $100 proximity switches can be very useful in shortening the reaction time to unforeseen process challenges. The Fraunhoffer institute is pioneering in the implementation of capacitive “vision” In the linked article by Dr. techn. Norbert Elkmann the usefulness of advanced sensing is explored. “Manufacturing has great need of robots with high load carrying capacity for human-robot collaboration. Since the potential risk for humans in the event of a collision is naturally greater than when robots are smaller, the use of robots with high load carrying capacity in the direct vicinity of humans requires smart sensor systems such as capacitive sensors that detect proximity.” http://www.iff.fraunhofer.de/en/business-units/robotic-systems/capacitive-sensors.html
As we continue to use robots to replace humans, It will be necessary to create robots that incorporate human sensory capability. Touch will be one of the first areas that changes. Since material handling is one of the primary robot uses, controlling the applied force is a requirement. We have all been frustrated with the robot gripper in the arcade game. It drops the prize at every opportunity. If we wish to use a robot to replace humans the gripper needs tactile sensors. This mimics human touch using a strategy similar the human it replaces. Nerve endings, concentrated in our finger tips, transmit a whole bunch of data down the arm
Grippers have evolved from the arcade version to the state of the art Tactilus Multi-vector Sensor - Sensor Products Inc

Grippers have evolved from the arcade version to the state of the art Tactilus Multi-vector Sensor – Sensor Products Inc

Just force sensors by themselves may not be enough. It may also be necessary to have individual finger motion control. Other tasks arer even more sophisticated. Simply having force sensors may not be enough to prevent impact damage. The Lexus like most modern passenger cars has a ring of impact sensors around the body. Even though rush hour feels like bumper cars some days, it is not very effective to wait until the sensor detects contact as a strategy for safe following in traffic.
by METRO66 Wheeler Dealer Bumper Cars by Mariordo Driving Google Self-driving Car

by METRO66 Wheeler Dealer Bumper Cars
by Mariordo Driving Google Self-driving Car

As we look into the future of robotics, we will see a massive increase in the amount of data that is processed to accomplish the robot tasks. The current individual wires down the arm will be replaced by arm end processors and fiber optic links. Full vision control will occur in high volume premier applications, but cost limitations will result in selected use for other industrial tasks.

KISS

KISS also applies to automation

KISS also applies to automation


KISS — Keep It Simple Stupid
Early in my career I was assigned the task of commissioning an $70,000 electric paint robot. Unfortunately at that stage of robot evolution, the seal design at the robot joints prevented it from painting more than the first part. The vapors shorted it out. What I learned is that it is more effective to tackle automating the simplest tasks first. Simple tasks take less investment to automate. Even though modern 6 axis robots can now handle painting tasks, combining them with required sophisticated guard enclosures places them far from the KISS category in my mind.
I was watching a 2 axis gantry “robot” carry engine cylinder heads at a Honda assembly plant in Alabama. Reminded me of a dog playing fetch with a stick. The jaws of the gripper opened and the human at the end was presented with the retrieved cylinder head. I install gantry robot transport systems for the same benefit, their simple motion and guards allow humans to safely work along side them. These robots do not care that I am comparing them to a dog. As Ada Lovelace wrote as her work began the digital age “The Analytical Engine has no pretensions whatever to originate anything. It can do whatever we know how to order it to perform”
A Spaniel fetches a stick by Kleuske

A Spaniel fetches a stick by Kleuske

Kiva robots are even simpler. They race to the other end of the warehouse and wait like puppy dogs for us to collect the item they have retrieved. All of this without the clutter of the rails and guards of gantry retrieval systems.
Moore’s law marches on. The cost of computers has dropped to the point where we can afford to automate even simple tasks. It is easy to write down date, starting odometer, location, finishing odometer and purpose for one business trip. You get pissed off enough to invent a better way when you spend a chunk of every Christmas vacation inputting a list of a thousand or so business trips so that you qualify to keep the $8000 to $9000 dollar business mileage deduction. I want to use the KISS principle to fix all the aggravations in my life.
Capture your full mileage deduction

Capture your full mileage deduction

It is nice that an affordable computer http://mileagetrakker.com can talk to the car and generate the log for me

Artificial Intelligence

Artificial Intelligence

Artificial Intelligence

Back in my early engineering days I was using the largest Cray Research computers in the world to analyse the stress and mode shapes of cars and trucks. This only worked if we could simplify the finite element test to the point where the computer could complete the calculation starting at 7:00 pm and stopping at 5:00 am when its task changed to supporting CAD. When I discovered that one of my friends had a personally owned computer of this magnitude at his desk I was intrigued. He had discovered that neural networking programs that simulate the way your mind tackles problems could be used to make a 6 figure income on the stock market. I linked him into some university researchers who discovered that complex numbers were more effective within neural networking programs. He traded this improvement into a 7 figure income. This is where computerized artificial intelligence shines. Keeping track of enough of the whole economy to succeed at managing a stock portfolio is beyond our mental capacity.
The engineering community continued to advance its versions of artificial intelligence. We call it adaptive control. Early examples include electronic spark advance. By 1982, it was finally possible to purchase power transistors that were capable of handling the spark control task. Later advancements included electronic fuel injection, which continuously adapts to dirt buildup, wear. and driver behavior. In military applications, stealth bombers and Ospery aircraft are beyond the ability of pilots to fly without adaptive computer assist. Along the way, I invented an industrial process which an operator could not supervise without the help of my patented adaptive control.

Slurry on Demand

Slurry on Demand


There is a perfect storm approaching. It will affect the people working for the big accounting firms the most. During World War II the Allied intelligence community invented what became to be called content analysis. They guided the war effort by combining the information gathered from every publication, like company newsletters and local news sources, that they could get their hands on. Any one item was not useful by itself. The company owners (stockholders) created the concept of accounting firms to look after their financial interests. The crooks who orchestrated the major scandals such as the World Com collapse took advantage of their incestuous relationship with the accounting firms doing the stockholder oversight, to mask their actions. Firms that are actually hired by crooks are reluctant to blow the whistle. The advent of big data combined with the evolved capabilities of the neural networking side of artificial intelligence are staged to crash onto the scene. Computers using artificial intelligence and content analysis will detect an impending company failure. The resulting analysis will enable a few stock investors to sell and get out. The stockholding public will have their confidence shaken. The lack of confidence in traditional accounting oversight will cause an accounting lean revolution where new more efficient controls emerge. We are all in favor of lean improvements until our own salary is the target. Lean improvements in manufacturing have left accounting expenses as a big target for computer technology inspired cost reductions. Usually this occurs as a season change in method.

Lean Automation

Mileage Trakker verses Fanuc ARC Mate 120iC/10L taken by Phasmatisnox

Mileage Trakker verses
Fanuc ARC Mate 120iC/10L taken by Phasmatisnox

I have to admit that many years of installing robots to reduce labor has blinded me into thinking of automation as robots to be installed. This matched the marketplace because the $200,000 robots morphed into $50,000 robots opening the door for new applications with each price drop. Shop floor manufacturing cost which was $.50 of every sales dollar in the 1950’s has steadily declined to $.20 of every sales dollar today. Since 80% of the current business costs are not on the manufacturing floor, it is not surprising that the best opportunities for reducing cost by automating are no longer on the shop floor.
It would be naive to claim that no automating activity has occurred off the shop floor. The PC, then smart phone revolutions, have brought the efficiency of software to our fingertips. We would not even consider typing and mailing a letter anymore. PC Office suite software is now available as “free” open source downloads. The more recent smartphone market is equally mature. Even as early as 2010, 90% of the smart phone apps sold less than 100,000 copies, which suggests that they failed to cover their development costs.
The 80% share of business cost off the shop floor shows that the current opportunities are still away from the shop floor. The developers agree and the latest excitement is centered around innovations that combine software and hardware. This is consistent with what I am seeing. Somewhere in the future your cars will have enough connectivity and spare computers or your cell phone will have enough battery capacity to handle extra tasks. In the short term dedicated devices such as the mileage trakker http://mileagetrakker.com that I market are good examples of the latest trend. Business people who travel are happy that a device plugged into the car handles most of the assembly of an IRS format mileage report so that they can receive their significant mileage deduction at income tax time

Demand

DEMANDtransmission
The introduction of new electrical users such as electric cars are keeping electrical rates on the radar screen. I tend to agree with Elon Musk that this will cause the electric utility industry to expand their infrastructure. Usually changes like this are accompanied with an increase in rates. Most businesses will be pressured to consider actions that will control the cost increase. Reducing demand charges is one of the best ways to continue to obtain the energy needed at a more affordable cost.
“Saving Money by Understanding Demand Charges on Your Electric Bill” — This Tech Tip explains demand charges, how they are calculated, why we need to monitor them, and what we can do to lower them. Demand–related charges usually represent 30 to 70 percent of most commercial customers’ electric bills. Electrical demand in some parts of the Nation stretched the capabilities of electrical generating and transmission systems during the summer of 1999″ Dave Dieziger, Project Leader US Department of AgricultureDEMANDelectricLOAD
Many process cells have a spike load which is much higher than the average load. This fact opens the door for reducing demand charges

Leveling the peaks- The size of the wires (and generating equipment) is directly related to the maximum demand that your equipment requires. Historically we had few affordable options for reducing the peak. With the advance of modern computerized electronics, better options exist. In a recent installation a soft start on a 200HP motor proved very cost effective. OLYMPUS DIGITAL CAMERA Even discounting the future energy saving, it was possible to cover the extra cost simply by reducing the size of the wires feeding the machine. It is interesting that more than the power company is concerned with wire size.
Automation is becoming a popular business survival technique. Virtually all automation requires electric power. The wires feeding an existing cell (or transformer feeding the plant) may not be sized to support added automation or robots and handle the spike loads. In many cases it is cost effective to reprogram the PLC computer running the cell to level out the spikes. This frees amperage to run the added automation. In the die cast rebuild I accomplished last year this turned out to be nothing more than adding program steps to insure that all users did not grab power simultaneously. 100 amps out of 450 amps became available for auxiliaries. Yes a slight increase in cycle time for this change occurred. After I was done, this cell in total had a quicker total cycle time because I overlapped other actions.

Filling in the valleys – We are seeing process controllers, software, tooling and equipment evolve to the next technology level. In mold making this can be disruptive. Historically we we pleased when the cutter path software could simply create the shapes. We used large margins to insure that power demand did not exceed the supply. Most of the time the mill motors were barely off of their minimum power. DEMANDmill
Recent advances in milling cutters and driving software have made it possible to stay at 70% spindle power instead of 10%. The reduction in time from 3 days to 1 for removing the 6000 lbs of chips to create a mold holder is disruptive to the CNC build marketplace. The CNC machine builders will have to adjust to selling less machines.

Storing energy – Many hydraulic powered machines use accumulators to store energy and balance demand. The original equipment builders in many cases did not work with the end user to optimize this storage. OLYMPUS DIGITAL CAMERA
My recent rebuild at Canadatum showed that it is possible to level the power usage of the machine by paying careful attention to the timing of the recharge.

Combined together engineered power management has can knock 10% or more off of the power bill.

Embedded Lean

NOfat
Lean automation applies to all aspects of business. With the cost of computing declining as predicted by Moore’s law, we can now afford to multiply the talents
of a few excellent lean practitioners across a wider audience. This trend is matches the activity occurring in higher education where online courses are now becoming the norm. The modern computerized telecommunication miracle is leveraging the talents of the best educators across the world education system.
The secret is providing lean information at the time that it is needed. We could care less about the avalanche of medical knowledge but are extremely interested in the
specific tid bits that apply to our current malady. Blood pressure cuffs that know exactly how to automatically take a reading are a good example of embedding the skill of nurses
as an automated computerized embedded lean device.
Manufacturing has evolved from plants making a few million identical Chevy Caprices
to customized JIT manufacturing on demand. This mass customization would not be
possible without the computerized ERP, TMS and work instruction systems that provide the correct information as it is needed.
The simplest tasks sometimes have the biggest payback. It takes next to no effort to flip a light switch. Most of us have the skill to perform this task from the time we are two years old. A major cost saving is possible by implementing computerized sensors that simply turn off the light when the room is unoccupied.
Technology needs to be the servant and not the master. An “app” for your smart phone that routes you around unseen traffic tie ups saves major time in your life schedule and controls wasted fuel. Plugged into my car is a Mileage Trakker http://mileagetrakker.com that creates an IRS mileage report at tax time without me remembering to turn it on. On the opposite hand, I was talking with one of my truckers who indicated that he chose to move to another sector of the trucking industry because his former employer implemented a computerized ball and chain that rigidly enforced perfect compliance to inflexible rules.
Our lives will be better after we learn to apply the lean benefits of lower cost computing.

Wingman

Who is watching your back?

Who is watching your back?

In this high tech world it is comforting to know that you have angels looking over your shoulder. For example you have a computer wingman driving with you every mile of the way.  You won’t believe me until you try to drive a Model T where the spark advance is controlled by the driver using a lever attached to the steering wheel.  It is very easy to stall the engine each and every shift by getting the spark advance wrong.  Technology done right, like computer controlled spark advance, is user invisible.

 

Ford Model T opened driving to the masses

Ford Model T opened driving to the masses

We all get frustrated with new technology that requires the skill of a rocket scientist to operate.  Robotic and CNC manufacturing machinery that was introduced in the 90’s fit in that category.  The computer processor in that equipment was barely able to keep up with running the equipment and did not have any leftover capacity to assist the user.  The good news is that we can now afford lots of computer capacity as Moore’s law predicted.   Multiple large capacity computers are embedded into just about everything we currently create.

The secret is in creating useful tasks for these computers to do.  A computerized “wingman”,  who bridges the gap between the bits and byte and the user is one of the most helpful tasks.  I work with Wesley an industrial vehicle builder who offers an autonomous tug vehicle.  This technology would not have the market interest or acceptance if it required a rocket scientist to purpose it for the task. The embedded “wingman” in the computer control enables a normal warehouse worker to program a delivery,  simply by driving the route it the first time.  Other good examples of invisible computerized “wingmen” include the Milage Trakker http://mileagetrakker.com plugged into my car that collects and tabulates the mileage that I drive without me having to think about it.  It also understands and interprets the engine error codes with information provided real time to my smart phone.

I am not sure that I pictured the angel looking over my shoulder as a R2-D2 robot.  As computers invade every aspect of our lives I am beginning to believe that this is exactly what I need.

Reinventing The Wheel for Lean Logistics

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Mankind started out as hunters and gatherers.  As this Chinese proverb reminds us, “Man who sits on side of mountain waiting for roast duck to fly into mouth, waits a long time.”  The goods were not coming to the man.  … Continue reading