Take care of loose ends

Problem: When inserting very large diameter stripped cable into a crimp terminal or lug, the wire strands become frayed or bent. How can the wire ends be kept together to fit into the connector?

Solution: Use a small worm gear hose clamp to compress the stripped strands into a tight bundle that fits into the terminal lug. Remove the clamp after crimping is finished.

Contributor: Pete Gallant, Electrician, Aerovox, New Bedford, MA.

Band control

Problem: Bundles of steel come into the shop tied with steel banding. When the banding is cut it can whip around and cause damage. How can the banding be controlled so it is not hazardous?

Solution: Fold a welder's blanket or other heavy cloth into a strip approximately one foot wide by 6 feet long. Drape the blanket over the steel banding to be cut. The banding is safely trapped under the blanket.

Contributor: Bob Bobnar, Facilities Engineer, Presrite Corp., Cleveland, OH.

Dead center

Problem: It is often necessary to center punch the end of an existing shaft for drilling to add additional components or rigging points. How can you be sure you are in the center of the shaft, especially larger ones?

Solution: Turn the shaft at a low rpm. Place the center punch on the end of the shaft. You will only be able to hold it still if it is in the center of rotation. When the shaft stops, strike the center punch.

Contributor: Michael J. Lembo, Sr. Principal Project Engineer, CertainTeed Corp., Blue Bell, PA.

The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Pipe fabrication and IIoT; 2017 Product of the Year finalists
The future of electrical safety; Four keys to RPM success; Picking the right weld fume option
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Power system design for high-performance buildings; mitigating arc flash hazards
VFDs improving motion control applications; Powering automation and IIoT wirelessly; Connecting the dots
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

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This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
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This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
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