Applied Research Type: Manufacturing

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Packaging dreams by robot

Bright and shiny lottery tickets get purchasers seats to fantasyland—a destination so popular that it’s hard for Pollard Banknote Ltd., a leading global producer of high-volume gaming tickets, to keep up with the high demand for the tickets it produces in its facility in Sault Ste. Marie in Ontario. But for Pollard to expand its market it needs to make its packaging more efficient — by automating with robotics. That need led it to partner with Sault College researchers, who were asked to develop custom software, and to design and deploy hardware in the College’s Robotics lab.

By working with Sault College and their team, Pollard Banknote can draw from their previous experience and work offline in the college’s Robotics Lab to develop and test an improved solution that will meet their needs. Through NSERC’s funding support of this project, Pollard’s costs to innovate will be reduced and the risks will be minimized, making it feasible.

Currently, the gaming tickets are processed on assembly lines before being transferred to packing station where they are boxed and put on pallets manually, in a variety of different configurations to meet customers’ specifications. Switching to robotics will allow the heavy boxes from multiple product lines to be sorted onto pallets by machine. The streamlining will improve efficiency and save money.

Three College staff members and two students worked from May to December of 2016 to develop communications, grippers and sensing systems, as they proved the concept on five representative products from Pollard. The company was convinced by the work to buy the technology used in the project. The students working on the project learned new skills in programming robots and project management may have an opportunity to work for Pollard Banknote once the equipment is in place.

Industry: Manufacturing

About Sault College

Sault College is located in Sault Ste. Marie, Ontario and aims to provide a transformative life experience through empowering students to think and learn in... Learn more
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Plugging into a new housing concept

Family dynamics in Canada are fast becoming more diverse, but the housing industry has been slow to adapt to them. It used to be that families remained in one house for decades or even generations. Today, according to the Vanier Institute of the Family, each Canadian on average owns five houses over a lifetime, upsizing and downsizing as children are born, age, and eventually move out of the nest. Often, families renovate rather than move, which can be an expensive and disruptive process.

This is making the traditional notion of the family home obsolete. Families today need innovative housing models that can quickly and easily adapt to their changing needs. One possible solution is a housing model that can expand or contract as a family evolves. But adapting house models requires adapting everything in them — so this research project examined “plug-in” electrical circuits that can be snapped in and out as needed.

It was visionary Okanagan developer Andrew Gaucher, president of the Okanagan chapter of the Urban Development Institute and of Catalyst Land Development and its parent company, G Group, who approached Okanagan College in 2016, asking for research assistance to explore his idea.

Gaucher teamed up with a 17-year-old carpentry student, an electrical apprenticeship student and an electrical trades instructor, who is an emerging researcher, to explore the possibility of developing a revolutionary concept for housing units. Gaucher wanted help to realize his vision of living-space modules that could be joined and separated again.

“To bring this idea of modularity to reality we need to think about making it easy for families to add another module to their home or take it away as things change,” says Gaucher. “Safe, reliable, dependable and easy connections are vital. And while you’d think there were already-developed systems that meet that criteria, I wasn’t able to come up with any. The idea is to move away from hardwiring all connections to the grid.”

Investigation let Okanagan College researcher to recommend a plug-in system for electrical wiring that’s already commonplace in heavy industry. This system was chosen because it was weather resistant, complied with the Canadian Electrical Code and homeowners can operate it safely and simply, even when the electricity is connected. Now, with the electrical problems addressed, Mr. Gaucher is tackling other construction and infrastructure issues for his adaptable housing.

“I really appreciate and value the support of the College, Luke, and Noah, and the federal government,” Gaucher said. “The opportunity to innovate and create or refine different approaches to housing needs is clearly here and it’s tremendous to have this kind of resource at our fingertips in the Okanagan.”

Partner(s): The G Group
Funded by: Applied Research and Development (ARD) Grant, College and Community Innovation Program, The G Group

About Okanagan College

Situated in one of Canada’s most picturesque and dynamic regions, Okanagan College offers more than 130 different programs, and credentials that range from certificates to... Learn more
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Easier video surveillance

Lanoptic Video Solutions Inc. designs, sells and supports digital video devices for security and surveillance. It recently developed a system for installing digital video cameras that combines the mounting system with tools and a fastener. Called Novattach, the system makes cameras much simpler and faster to install than traditional methods.

Lanoptic, however, wanted to reduce the device’s overall cost without affecting its functionality and turned to researchers and students at Durham College for help, with a goal of ultimately creating a family of engineered solutions.

Two students from the Mechanical Engineering Technology Program worked on this project, creating designs for the mounting bracket and 3-D printing the prototypes. The students involved got to use the latest manufacturing technology, as well as developing a broad range of skills, from project planning and management, prototyping, researching material, sourcing components and choosing suppliers. They also had to make presentations, collaborate and manage conflict — all increasing their likelihood of being hired quickly after graduation.

The project was a key step towards the commercialization of Novattach as a highly competitive product. The new mounting bracket enabled Lanoptic to capture 10 per cent of the digital camera installation business in its first year. The company expects to get more orders, expand into new markets, and bring manufacturing of the product to Canada, creating jobs and a positive economic impact.

Industry: Manufacturing
Funded by: NSERC

About Durham College

At Durham College, the student experience comes first. With campuses in Oshawa and Whitby, Ont. along with a learning site in Pickering, the college offers... Learn more
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Flying out of college to a job with kiteboarding innovation

Ocean Rodeo came to Camosun College with a problem. The company, a kiteboard manufacturer, wanted to build a new kind of composite control bar for kiteboards — but could a “plastic” bar hold up to the rigours of kiteboarding?

After meeting with the Camosun Innovates team, Ocean Rodeo agreed to partner with the college on an NSERC Engage Grant, and first year mechanical engineering technology student Ben Costin was hired to work part time with Camosun Innovates on the project. Ben conducted a series of destructive tests that mimicked and exceeded the stresses and forces that kite-boarders would put on the bar used that controls the kite and influences where the boarder is heading.

Ben’s controlled studies showed the bars were breaking in roughly the same place with identical patterns. With the help of a local expert in injection molding, he created an injected-molded control bar, which ultimately solved Ocean Rodeo’s breakage problem. The new bar has since been launched with great success; some call it a game-changer for kite-boarding.

The company was so pleased with the results of the collaboration it worked with Camosun Innovates to pursue a three-year NSERC Applied Research grant to continue their joint research and development efforts. The funding allowed Camosun Innovates to hire Ben after his graduation to work with Ocean Rodeo on designing and fabricating other prototypes.

Industry: Manufacturing
Partner(s): Ocean Rodeo
Funded by: College and Community Innovation Program

About Camosun College

Camosun College is located in beautiful Victoria, British Columbia. Our two campuses serve approximately 18,000 learners a year in certificate, diploma, bachelor’s degree and continuing... Learn more
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Power line research shocks and impresses

Shannon Developments Corp. assesses power lines around the world. For more than 20 years its assessments have helped utilities to replace only the power lines that are wearing out, instead of going through scheduled replacement, which may mean lines that are still performing are taken down.

Recently, Shannon’s assessment process has evolved toward digitized analysis — and company owner Douglas Shannon needed samples of power lines that had deteriorated in different ways. With them, he could create digital files to be used in an analytical computer model. Rather than using actual corroded power lines for his research, Shannon needed a method to simulate aging on conductors.

“This is a very high-stakes game for utility providers because of the expense to replace the lines,” Shannon said. “Creating this analytical system from the physical models will allow us to provide our clients with a comprehensive and cost-effective assessment of their aging power line infrastructure.”

Shannon approached the Southern Alberta Institute of Technology (SAIT) to undertake an applied research project with design, testing and fabrication researchers in the institute’s Applied Research and Innovation Services (ARIS) department. The researchers created 15 samples of simulated power lines affected by different types of corrosion.

“Now that we have the physical samples, we’re looking to create the digital models that reflect them. These digital files will then be used in an analytical computer model,” Shannon explained. “What has been advantageous for me about working with [the Applied Research and Innovation Services department] is that it allowed me to focus on the computer model while researchers developed the physical samples, very hands-on work that required a lot of time and attention to detail.”

There were also advantages for SAIT students who got an opportunity to collaborate with SAIT researchers on the work, and for utility companies which will ultimately get efficient, fast and accurate information about the state of their power lines and whether they need to be replaced from this multi-faceted research.

Industry: Manufacturing
Funded by: Engage Grant

About SAIT

SAIT (Southern Alberta Institute of Technology) is a leader in action-based learning, delivering relevant, skill-oriented education. We offer two baccalaureate degrees, three applied degrees, 73... Learn more
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Refining brewing at Refined Fool Brewery

The idea of students getting immersed in beer doesn’t exactly go hand in hand with words like “efficiency” and “productivity,” — but they did when a group from Lambton College worked with Refined Fool Brewing Company, a micro-brewery in the heart of downtown Sarnia.

Refined Fool approached Lambton College for help in minimizing the space and labour their brewing process required, while increasing energy savings, efficiency and productivity. The first part of the project allowed the brewers to monitor the brewing process off site using smart devices. The second part automated keg washing, which was previously done by hand.

Faculty Researcher Kevin Ryan and three students from Lambton’s Instrumentation Control Engineering Technology program worked in collaboration with the Refined Fool team to implement the new technology in their facility.

Refined Fool’s partners say working with Lambton College helped increase profits and reduce production and operation costs.

Partner(s): Refined Fool
Funded by: Applied Research and Development (ARD) Grant

About Lambton College

As a post-secondary leader in education, training and research, Lambton College has experienced tremendous growth in recent years. In addition to a significant rise in... Learn more
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The SeatBOT: automating quality assurance

Up, down, forward, back, straight or tilted or down, push button or lever — car seats have a whole range of motions that have to work. A team from Humber College helped to build a system to let auto manufacturers test that range robotically.

The Humber team – faculty members Neal Mohammed and Mohammad Al-Rady, and electromechanical engineering technology students Theodor Willert and Joshua Donnelly-Robertson – worked with industry partner 416 Automation Inc. to build SeatBOT, which eliminates the need for a person to do the functional and electrical tests automotive seats require.

SeatBOT can automatically test buckles on seatbelts, power seat buttons or manual track bars and levers, and any other features of seats in vehicles. Customers now want the SeatBOT as a standard on all test equipment.

The prototype developed with the Humber team is already a huge success for 416 Automation, which has sold five SeatBOTs around the world (two systems are already running in production) and has more clients interested in purchasing the system. It also worked out well for Humber students, who have been hired on at 416 Automation as a result of their participation in this project.

Industry: Manufacturing
Partner(s): 416 Automation

About Humber Polytechnic

Humber Polytechnic is one of Canada’s leading postsecondary institutions, combining deep theoretical learning with applied, hands-on experience. Humber offers a wide variety of credentials including... Learn more
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Innovation in free flow as students redesign fountain technology

The sight of water dancing in a fountain always captivates — but how many of us give any thought to how that magic comes about? Today’s elaborate fountains are masterpieces of mechanical engineering; and, Toronto-based, internationally known Crystal Fountains recently turned to Humber College for help with design.

The challenge Crystal Fountains brought to a team of faculty and students from Humber’s School of Applied Technology was to build an electromechanical drive system for fountains, which they felt would be more cost effective and reliable than a traditional pneumatic system. The deliverable Crystal was looking for was a fully functional machined nozzle.

Students, working with Professor Hassan Hassan, built a prototype drive system that switched the power source and was more reliable, controllable, and compact than the pneumatic model. They also built a new nozzle with an innovative ball design and enhanced performance tension cables. It has much higher motion capability than previous Crystal Fountains models, but thanks to innovative mechanical techniques, it’s both smaller and less complex than older designs.

The students used electromagnetic components and couplings as well as electrical motors to power the nozzle instead of a pneumatic system and redesigned the nozzle to provide a broader range of tilting and rotation, which gives more control over how the water moves.

In the end, the students had created a nozzle that can make water dance and swivel from every possible angle, sequenced to music and lights. The project greatly enhanced the students’ design skills, highlighted Crystal Fountains’ creativity and innovation and gave the company a unique advantage over the competition.

Industry: Manufacturing
Partner(s): Crystal Fountains
Funded by: Crystal Fountains

About Humber Polytechnic

Humber Polytechnic is one of Canada’s leading postsecondary institutions, combining deep theoretical learning with applied, hands-on experience. Humber offers a wide variety of credentials including... Learn more
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Students learn to lean

A Saint John company’s need to improve its processes provided New Brunswick Community College (NBCC) Students with an excellent opportunity to improve their mechanical engineering skills.

Bourque Industrial, a company that does custom fabrication of carbon steel, stainless steel, nickel alloy and aluminum — both new parts and repairs — approached NBCC for help improving productivity and efficiency. The company’s systems hadn’t kept up with growth and expansion over a number of years. After discussions with Bourque’s CEO, engineering technology instructor Bill Chamberlain saw an opportunity to turn the company’s problems into applied research projects for mechanical engineering technology students at the college’s Saint John campus.

Two projects were developed to align with the competency requirements of the lean manufacturing course. The first project was to apply lean manufacturing techniques to Bourque’s fabrication shop to increase productivity while reducing the space used. The second project applied lean manufacturing techniques to Bourque’s project management.

The students worked directly with the company, with Chamberlain available as their technical advisor. He says the work adds value to what they’ve learned in the course: “It allows them to get a hands-on experience applying lean manufacturing techniques in a real-life situation.”

Bourque CEO Rick MacMichael called the projects a win-win situation “where the students get to apply their education to a real manufacturing situation and we receive the benefit of their lean manufacturing techniques, improving overall productivity in the shop.”

Industry: Manufacturing
Partner(s): Bourque Industrial
Funded by: National Research Council - Industrial Research Assistant Program

About New Brunswick Community College

With over 90 regular programs and six campuses across New Brunswick, New Brunswick Community College (NBCC) is a collaborative, learner-centred college – creatively contributing to... Learn more
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The fine art of 3D printing

Alongside the wheels and kilns in the pottery studio at Mohawk College’s Stoney Creek campus is a new way to create art — a 3D printer for ceramics.

Two faculty members of Mohawk’s Continuing Education program, Duncan Aird and Reid Flock, collaborated on this revolutionary work. Their ongoing quest for innovation in the classroom and expertise in ceramics was the spark that lead them to create new courses to take advantage of the computer software designed for producing ceramics in a 3D printer.

The project leads used Mohawk College’s Additive Management Resource Centre to help them choose the best 3D printer for ceramics.

The first 3D ceramics course, “3D printing with clay,” began in the summer of 2017.

Industry: Manufacturing
Funded by: Mohawk College Applied Research and Innovation in Education Fund (ARIE)

About Mohawk College

Mohawk College educates and serves 30,000 full-time, part-time and apprenticeship students at three campuses in Hamilton, Ontario. More than 1,200 international students from over 70... Learn more