A.G.M. Michell Award 1988
JOHN R. ALLEN
Aspects of Mechanical Engineering and the Sugar Industry
College of Mechanical Engineers
The Institution of Engineers, Australia
A22354476B
Gardens Point A22354476B
Aspects of mechanical engineering and the sugar industry
JOHN ALLEN
Dr John Allen has been chosen by the Board of the College of Mechanical Engineers to be the recipient of the 1988 AGM Michell Award. Dr Allen was born in Sydney and attended Sydney Technical School. He served his apprenticeship at the Garden Island Dock Yard and graduated with honours in Mechanical and Electrical Engineering from Sydney University. He was a member of the teaching staff in Mechanical Engineering at the University of new Soth Wales from 1951-1959 inclusive. He then spent two years with Carrier as Manager of Technical Services before joining the Sugar Research Institute as Director.
Dr Allen is known widely for his contribution to the Australian Sugar industry. After nearly 25 years guiding the progress of the Sugar Research Institute, Dr Allen retired from the position of Director at the end of November 1986. Under John Allen's directorship, the Institute developed to its present position as one of the most technically advanced and productive research establishments for sugar processing in the world. An environment was built that provided both a high standard of facilities and equipment to attract highly trained staff and the tight interaction with mills required to satisfy industrial needs.
Collaboration with Universities, Colleges of Advanced Education and CSIRO Divisions in projects of special interest to the sugar industry was strongly encouraged.
Dr Allen also provided unparalleled personal service to other industry associations and societies, as well as educational and State Government bodies.
He served as President of the Queensland Society of Sugar Cane Technologists (now the Australian Society of Sugar Cane Technologists) during 1974/75. He was awarded life membership of the Society in 1986.
On the international scene Dr Allen was Australia's Regional Vice Chairman and Coun- sellor of the International Society of Cane Technologists and chairman of the Factory Engineering Section at five congresses. He was awarded life membership of the Society in Indonesia in 1986.
As part of his service to education, Dr Allen was instrumental in founding the Mackay University Centre and has been a member of the Council of James Cook University of North Queensland and of its Faculty of Engineering and of the Council of the Capricornia Institute of Advanced Education. Assisting government, he has served on environmental committees and was a member of the Commonwealth Council for Rural Research and Development.
His outstanding contribution to the sugar industry was honoured in the Australia Day
Awards in 1986 by his appointment as a member in the General Division of the Order
of Australia.
Aspects of Mechanical Engineering
and the Sugar Industry Library QUT
INTRODUCTION
Having spent the last 25 years of my working life as Director of the Sugar Research Institute, which was an administrative position rather than a 'hands on' mechanical engineering research occupation, I was shocked to be advised of my selection as the winner of the A.G.M. Michel1 Memorial Medal for 1988. Upon querying my being chosen, my attention was drawn to the guidelines for selection which are indicated in a note by M r . R.S. Davie, then Chairman of the College of Mechanical Engineers, included in the Mechanical Engineering Transactions, 1979. M r . Davie said ' The award was therefore named The A.G.M. Michell Award, and it was agreed that it should be conferred on the basis of either a highly significant contribution or contributions through technical innovation relating to the science or practice of Mechanical Engineering; or long-standing eminence in Mechanical Engineering science or practice; or notable and sustained leadership pertaining to Mechanical Engineering, within the Institution; or a worthy blend of the aforementioned.'
With humility, 1 accepted the award, recognising that I had been involved with a number of Australia's leading researchers for 25 years, and that this award should be recognised as a tribute to them and the contributions which our team made to the technology and prosperity of the Australian sugar industry. Accordingly, much of this paper includes indications of some of the contributions made by these researchers whose work may not be known outside of the sugar world. Although these discoveries and innovations may not have the spectacular impact of those made by James Watt and A.G.M. Michell, Australian researchers in mechanical engineering have in the past, and are at present, breaking new ground and solving problems comparable with those solved by the 'giants' recorded in history. Good research is being done outside, as well as inside, the boundaries of capital cities and universities.
As a second year apprentice fitter and turner at the Garden island Naval Establishment in 1940, it was with awe that 1 was shown, down in the bowels of a naval ship, an incredibly clever thrust bearing for transmitting the thrust of the ship's rotating propeller to the ship structure. I was told that this had been invented by an Australian engineer named Michell. It was a complete wonder to me that a man could think of using small tilting pads and a build-up in pressure with a wedge of oil, in a way that would transmit the tremendous thrust needed to push a ship through the water.
Previously, I had seen an outmoded thrust block design which consisted of a series of collars on the propeller shaft, each with horseshoe-shaped bearing blocks fitted between the collars. I was told that the bearing faces needed attention at frequent intervals and it was clear to me that the Michell design was much more compact. In later
years I recognised the elegance of the design, its simplicity and its practicability. What an instructive example it is of the application of mathematical concepts to practical engineering design.
George Anthony Michell was born in 1870 when his parents were visiting England. The family returned to Australia and Anthony Michell enrolled at the University of Melbourne, graduating with a B.S.C.
in 1987, gaining first place in civil engineering and second place in mining engineering. He
obtained his Master of Civil Engineering degree from Melbourne University later. Michell had emerged from his educational environment as a man with excellent mathematical ability and a bias towards using this ability in the solution of engineering problems.
Professor Osborne Reynolds of Manchester University, whose work forms the basis of much of our knowledge of fluids in engineering, had written, in 1886, a paper describing the two- dimensional behaviour of a film of lubricant. He drew attention to the need for the thickness of the film to decrease in the direction of the motion of the surface if there were to be a build-up of pressure within the film. Michell had worked with pumps and turbines, had encountered the necessity to accommodate thrust in the axial direction and recognising the value of Reynolds' findings, he undertook fundamental research in 1902-1904 to generalise that work for application in engineering.
Michell displayed versatility in his contributions to engineering knowledge. He published some early work on frame-structures, moved into hydraulics, then into fluid mechanics and lubrication. His thrust bearing received international recognition and adoption. This was his most successful achievement and by 1915 these bearings were being installed on almost every ship. His journal bearing using the same principle was an engineering success but, since there were in existence good alternative bearings, there was no demand for it.
The crankless engine followed. In this design a collar was set obliquely to the shaft, which upon rotation imparted reciprocating m o t i o n , parallel to the shaft, on a number of pistons arranged in a circular array. when the shaft was driven, this mechanism provided a pumping action; the swashplate pump, using this principle, has found many useful applications. Alternatively, the mechanism could be operated as an engine, by using the pistons as the source of power. A wide range of internal combustion engines and compressors were built to his design. It is regrettable that Michell's renowned engineering ability was not matched by business acumen, which could have resulted in much greater financial rewards for his outstanding work.
Michell's versatility is evident in the 48 patents bearing his name. His approach to problem solving was well described by Professor A. Robertson w h o , in comnenting on a viscometer produced by Michell said '... a typical Michell invention: a mathematical analysis and then a clever device to effect the desired end.' (1)
N o w I wish to draw attention to some of the unsung 'champions' of mechanical engineering who have done so much for one of our Australian industries, and to indicate the context in which their contributions were made. At the conclusion of this paper I have made some brief comnents on engineering education. These are based on my nine years on the lecturing staff of the University of N e w South Wales and 25 years during which period I was a Council member for various terms at the following institutions: the University College of Townsville, Capricornia Institute of Advanced Education and James Cook University of North Queensland. The latter 25 years coincided with my period as Director of the Sugar Research Institute.
In that position I had extensive collaboration with tertiary education institutions, CSIRO and industry.
THE AUSTRALIAN SUGAR INDUSTRY'S DEVELOPMENT.
In the present economic climate, we are being frequently reminded of the importance being placed on improving the financial performance of our industries. This is not a new concept for engineers, who generally have to prepare budgets and operate within them, as well as being asked to reduce costs of operations or of manufacture. To meet these challenges often means adopting new
technology. An indication of the importance of technology change to the profitability of an industry may be derived from the measurement of the propensity of an industry to adopt innovations.
Anderson and Stalker (2) measured technical change using parameters which described the transition process in terms of ultimate adoption and speed of adoption. The economic worth of a change, measured by its capital cost and payback period after tax, was related to the speed of adoption parameter and the resulting "innovation index1 determined.
They found the Australian sugar industry's index of innovation to be far higher than comparable food industries and that the only industries examined which had higher indices were those of aerospace and electrical engineering. Those authors attribute this high index largely to the unimpeded intra-industry information transfer in Australia's sugar industry which has resulted in many technological developments. In this paper I shall indicate some of the methods used to achieve the ready transfer of information and also indentify some of the 'champions' who conceived the innovations and others who made them work. This joining of forces has given the Australian sugar industry its pre-eminent role in the world sugar scene.
Since the turn of the century the Australian sugar industry has developed, from a small one with a relatively insignificant role in the nation's affairs, to a 1000 million dollar producer, exporting 80 percent of its 3.3 million tonne sugar production. This industry is located along a 2000 km coastal strip from north of Cairns in North Queensland, to south of Lismore in New South Wales.
Engineering developments in sugar mi11ing in the last fifty years have resulted mainly frcm the initiatives of that industry. In earlier years, the Colonial Sugar Refining Company Limited (CSR) led developments in all sugar matters and were responsible for such outstanding engineering contributions as the pressure feeder, which increased the crushing rate of mills. The Bureau of Sugar Experiment Stations (BSES) has assisted mills mainly in keeping abreast of technical developments in steam, electrical and chemical applications while concentrating its main efforts
in plant breeding and agricultural matters.
THE SUGAR RESEARCH INSTITUTE (SRI).
The Institute (SRI) was formed in 1949 and located in Mackay, the geographic centre of the industry.
It has every one of the 32 sugar mills in Australia as voluntary members, employs 60 staff and concentrates its research on projects related to the processes and activities of the raw sugar factories. It has a budget of $3 million which comes largely from the member mills and seme Commonwealth Government grants; recent changes in research grants are modifying the financial arrangements to some degree.
Control of SRI is through a Board of Directors comprising five members from the industry and two government nominees. This Board and the staff have served the industry very effectively. The Chairmen have all been industry leaders and all Board members have been highly regarded and supported enthusiastically. The present Chairman, Mr. R.
Deicke, a member of the Institution of Engineers, Australia, has been an outstanding helmsman.
Member mills have supported research because their experiences have demonstrated that well-conducted research is a profitable investment. Apart from the worth of regular research activities at SRI, the industry has learned that in the event of a crisis, the immediate availability of an experienced group to swing into action, is of inestimable value. The activities of SRI mentioned in this paper are confined to those investigations and projects which are pertinent to mechanical engineering. Although there is still a lot of old
equipment in sugar mills, the latest technology is applied where appropriate; for example, as early as 1971 a computer was installed at a sugar mill for control of some of the mill operations.
RESEARCH FOR THE SUGAR INDUSTRY.
The first group of engineers engaged by SRI included Dr. W. Crawford, who was a very experienced engineer with considerable mathematical ability, and D.S. Shann, whose engineering and management skills resulted in his becoming an industry leader in later years. These men had the task of convincing the very practical chief engineers of the industry, such as H.D. Donnelly, B.L. Wright, J. Hollywood, R.N. Jones, J. Batstone and others that a useful contribution could be made by the application of good analytical work and research into the industry's problems. Within a few years SRI's expertise was sought keenly throughout the mills.
Sugar milling requires heavy engineering equipment.
Some idea of the equipment may be obtained from consideration of the basic unit, the mill, of which there may be four to six in the milling train. A recently constructed mill (3) had two feeder rollers and three crushing rollers each weighing 42 tonnes. The size of the equipment and its location, remote frcm large cities, necessitates it performing reliably in service and requires that most repairs and maintenance be done on site by mill staff.
A valuable liaison was established with Professor Mansergh Shaw, (4) of the Department of Mechanical Engineering, University of Queensland, who led a team of researchers into a twenty-year period of fundamental research on the mechanics of milling.
At the university, a small experimental mill was constructed which used a rotating section of mill roller which pressed down onto a confined quantity of prepared cane as it was transported beneath the roller. This simulation of a crushing mill operation was remarkably successful.
SRI made a larger experimental milling installation at a nearby sugar mill alongside the milling train.
This experimental mill, with rollers about half the diameter and about one sixth the length of full- scale rollers, was similar in design to the conventional, operating mills. It was fed continuously with prepared cane taken from the main mill carrier; this enabled the experimental plant and measuring equipment to be run for a settling down period before the experimental runs of several minutes duration were carried out.
These two approaches were complementary and resulted in the establishment of world leadership, by the Australian researchers, in the mechanics of milling of raw sugar cane. At the beginning of the 1960's these researchers were using the very latest measuring equipment and were processing their data using a computer, when this was required. At the university were C.R. Murry, J.E. H o l t , B.M. M u n r o , K.J. Bullock, T.J. Solomon, and G . E . Russell, each of whom obtained his Ph.D. and made valuable contributions to the theory of milling. The text published by Murry and Holt became the classic reference for the sugar world on the subject.
Researchers from both groups published in the Proceedings of the Queensland Society of Sugar Cane Technologists Association (QSSCT). The SRI group worked with mill staff in applying this theory to the practice of milling.
During the 1960's the staff at SRI was increased by the addition of J.W. Hill ( 5 ) , D r . C.R. M u r r y , R.N.
Cullen ( 6 ) , W. McWhinney and M r s . E. Shepherd ( 7 ) . All except J.W. Hill had worked under Professor Shaw and they were engaged now in sugar milling projects or operations research at SRI laboratories and in the mills. Non-destructive testing was used extensively by SRI In this period. In addition to the magnetic particle testing of large gearing and other items, techniques were developed by J.W. Hill and J. M c G i n n , in 1963, to utilise ultrasonic testing equipment for detection of cracks in mill roller shafts. For example, a shaft which was to be put back into service was tested and found to have a major crack which would have caused failure within a few weeks of operation with all the attendant dangers of mill cheek fracture and major breakdown.
Increased crushing rates were needed urgently in the early 1960's, to enable the industry to expand and take advantage of favourable overseas markets.
Milling equipment was ordered but manufacture and installation of new equipment for the whole industry could not be done with sufficient speed.
Investigations of the existing intermittent feeding devices, examination of the feeding chute theories and measurement of chute pressures by D.S. Shann ( 8 ) , indicated the inadequacy of this equipment. He developed a light-duty feeder in which a pair of rollers was used to lightly compact the feed material before introducing it via a closed chute into the m i l l . These were installed immediately in most m i l l s , being readily fabricated in the mills' own workshops and installed during an interruption of crushing or at the weekend. These feeders enabled mills to utilise all the available power from the existing prime movers and increased significantly the capacities of the m i l l s . In 1967 a small computer, as part of a data-logging system, was installed in a mobile van which was transported to mills where major investigations were being undertaken. At that stage, use w a s being made of the digital computer at the University of Queensland and an analogue computer at CSIRO's Division of Chemical Engineering where D r . R. Batterham was extremely helpful. In 1969 an IHVI 1130 computer was installed at S R I ; in typical fashion, this was soon working day and night and weekends and had to be expanded in 1975.
Considerable relief had been obtained in the previous three years by the interconnection to the CSIRO's computing network through a node at S R I . This gave access to computers in Melbourne, Adelaide and Canberra as well as a gateway to data bases in North America. In 1983 a V A X 11/750 was
installed and facilities were provided for mills to access SRI Programmes using their own computer terminals.
The preparation of cane prior to crushing is done in a form of hammer mill known as a shredder. D.S.
Shann recognised that a relatively small increase in energy input into cane preparation facilitated the task of the milling train. Research by R.N.
Cullen in 1972 (9) together with experimentation by mill engineers such as A. Greenwood, J.W. W a t t , D.
Jacklin, C. Clarke and R.E. Bickle resulted in further leadership by the Australian sugar technologists. Installation of high-powered shredders gave fine cane preparation and enabled greater tonnages to be crushed by existing milling trains.
By the end of the 1960's the SRI researchers and the Australian mill engineers were the acknowledged world leaders in the theory and practice of sugar cane milling and this leadership has continued on into the 1980's. This success was made possible by the involvement of researchers from the university and SRI with the mill engineers. The readiness of the mill staff to introduce innovations and to persist in making the new ideas w o r k , together with their valuable observations were critical factors in this success story. Some of these mill engineers were graduates but most had made their way u p , from apprentice to assistant or chief engineer, by their diligent application to their work and private study.
An indication of the effectiveness of this co- operation may be obtained from consideration of one unit in a milling train which had been designed to crush 90 tonnes cane per hour in 1950. After some upgrading of power, addition of feeding devices and given better cane preparation, it was crushing over 400 tonnes cane per hour in the 1980's. Additional researchers such as D r . V. Mason ( 1 0 ) , Dr. D.M.
Jenkins, Dr. B. Edwards and J.D. Loughran joined in the milling research during the 1970's and 1980's and updated the earlier work to keep pace with the changes of preparation and the increased crushing rates.
W h e n the cane harvesting method changed from whole- stick to chopped cane harvesting, the length of the cane harvested reduced from two or three metres down to 200-300 mm. This advance in harvesting technique and convenience in handling, was accompanied by an accelerated deterioration of the sugar in the cane and a resulting elongation of the grain shape. This was unsatisfactory to the refiner. While microbiologists and chemists sought remedies in the field and factory, the mechanical engineers in SRI's operations research group set about reducing the time of transporting cane.
Initial attempts to increase the speed of the cane trains resulted in broken wheels and axles, bearing failures, uncoupling, broken draw-gear and derailments. A fatigue-test rig was set up to evaluate existing equipment and to check new designs; the rolling stock and track were found to be hopelessly inadequate for the higher speeds.
SRI assisted mills in the complete redesign of the transportation system including the rolling stock and the track which is of narrow gauge (610 m m ) . SRI developed scheduling systems and assisted mills with their implementation; these changes resultd in improved overall performance of the systems, with less rolling stock, fewer locomotives and greatly reduced cost of transporting cane. The time taken to transport cane from the harvester's siding to
the milling operation decreased, typically, from 30 hours to about ten hours. This resulted in negligible deterioration, and the grain elongation problem almost disappeared. The increased speed of cane trains led to SRl's development of radio- controlled brake vans, and later, a slave locomotive with a radio-controlled system which was about one tenth the cost of a conventional system.
This was typical of the work of S.R. Reichard who also developed a simple system for the installation of traffic lights where the rail crosses the main roads, an automatic cane bin identification system (11), and a telemetry system for tailbar torque monitoring (12); his innovations are to be found throughout the SRI equipment and the sugar industry.
Research by Dr. W. McWhinney, Dr. C.R. Murry (13) and R. James in the 1980's indicated that a well- engineered, large waggon of up to 20 tonne capacity, with two axles, could provide substantial savings over the smaller, typically four tonne, bins in use. To operate such long waggons on this narrow-gauge railway, having curves as small as 100 metre radius, necessitated some self-steering feature. Theoretical studies and experiments were undertaken to determine the forces on the wheelset;
the self-steering was accomplished by suspending the wheelsets by a sling at each axle-box. The sling, made of steel cable and arranged in a flat array, provided for 50 rnm fore and aft movement of the axle-box. This innovative suspension has been operated successfully for a complete crushing season, and, at present, commercial manufacturers are constructing prototypes of complete waggons incorporating this suspension technique.
In the early 1970's Murry and MrvVhinney (14) initiated a 'SUGAR' project which would provide a framework for linking the computer models of factory equipment to simulate sections of the factory. This total simulation of a factory has been a tremendous task, and in addition to the ongoing efforts of SRI staff, input came from IHWI, CSR and BSES. 'SUGAR' has been invaluable to mills when rearranging plant and planning expansions. It
economically-attractive sequence for the progressive installation of equipment, taking into account the improved performance of plant, overall, and the cost of each modification. When breakdowns have occurred, 'SUGAR' has been used to predict the performance of the plant if temporary arrangements were to be undertaken, then decisions have been made whether to await replacement of major equipment or continue crushing with the selected makeshift arrangements.
Bagasse is the ligno-cellulose by-product discharge from the mill after the sugar cane has been crushed and the juice taken away for processing. This is a valuable clean-burning fuel for steam-raising in the boilers, has about one third the calorific value of coal and is already in the factory.
Bagasse could be replaced as a fuel if cheap alternatives were available; this would make it available for many other purposes such as the manufacture of paper pulp, hardboard and cattle feed. R.N. Cullen and J.G. Loughran (15) led a group at SRI investigating methods of compacting the bagasse, which is of low-bulk density and therefore costly to transport and store. Valuable co-operation was enjoyed with the University of Queensland where Professor R.J. Stalker, D.S.
MacArthur and C.. Anderson (16) established, for bagasse, important relationships of the parameters, pressure, temperature, moisture-content, and the retention-time of a small pressure after the initial pressure is relaxed. At SRI, extensive experimental evaluations were undertaken with
bagasse; baling, pelleting and continuous rolling into a dense strip. Assistance was given by G.
Gartside and others of CSlRO's Division of Chemical Technology, in assessing the suitability of the densified product as a paper-making feedstock.
Over a period of twenty years, investigations at SRI and in mill installations, have enabled the Australian sugar industry to keep abreast of developments and applicability of 'cane diffusion'.
In the milling process the shredded cane is crushed and juice squeezed out, whereas in 'diffusion' the hot juice is applied to a moving bed of shredded cane, percolates through the bed and is then recirculated to leach out the sugar. Hot water is applied in the latter stage and the dewatering is usually done using mills. The Australian industry has two diffusers installed, but with its leadership in milling technology has not found the same attraction to this method of extraction as the South African industry.
Assistance in containing costs has been afforded mills by SRI's investigations including: track-
train dynamics, development of an effective system for the automatic recognition of truck numbers, the application of dynamic balancing to high speed machinery, minimisation of usage of fuel oil in stean raising, use of microprocessors throughout the plant and development of inexpensive systems for noise and air pollution control.
CSIRO COLLABORATION.
An important feature of having a CS1RO Board member has been the facilitation of liaison with the various Divisions. During Board meetings with staff present SRI was advised immediately of work being undertaken in CSIRO which was relevant, and accelerated progress resulted often from the ensuing collaboration. Examples of this include:
Hard facing of shredder hammers: CSIRO experience with rock drilling gave immediate impetus to the application of tungsten carbide tips;
Roller arcing: Roughening the surface of mill rollers enhances the feedability of the mill.
CSIRO researchers reccomended methods of improving adherence and reducing losses of the weld metal;
they also investigated methods of measuring the roughness;
Engineering materials: Investigations by CSIRO resulted in recommendations for metal in mill rollers to give improved strength and weldability;
Tramp iron separation: Scrap steel in the cane supply can cause severe damage to mill rollers.
CSIRO took part in experimental work at SRI to optimise the application of magnetic separators;
Large g e a r metrology: SRI Liaised with other industries to provide funds for CSIRO to design and build portable equipment which would enable the tooth form and pitch to be measured on large gears in remote locations. This obviates the necessity of transporting the large gears to the manufacturer in order to make matching gears.
UNIMPEDED INFORMATION TRANSFER.
Methods used to ensure that Australian mills were properly informed of the latest findings, included:
mill visits; conducting projects in mills throughout the industry; running training courses on special subjects and general courses on mill engineering; conducting symposia with input from
universities, institutes, CSIRO, commercial organisations, mills and SRI staff. Every effort was made to involve mill staff with SRI staff at conferences, at SRI and at the m i l l s . In addition, staff of SRI were enabled to collaborate with CSIRO Divisions, visit research groups in private industry, liaise with researchers in higher education establishments and attend important technical conferences in Australia and overseas.
Some delay was placed on communicating, to serious overseas competitors, research findings in sensitive areas which were likely to affect income from sugar sales overseas.
MANUFACTURERS' ROLE.
Throughout the sugar industry's development, many companies, including some of the larger ones such as Walkers Ltd. Maryborough, Bundeng, N . E . I . John Thompson (Australia) and North Queensland Engineers and Agents Pty. Ltd., made significant contributions to the progress of mechanical engineering. Leaders such as Dr. W. Hughes and D.G. Fry (17) were responsible for valuable development in their roles as managers and technologists; others from the manufacturing industry, including S.G. Clarke, G.E. Horsburgh, R.F. Beale, G . I . Frost and P.W. Levy (18) used their expertise in presenting the industry with modern designs which were manufactured with skill.
The provision of we11-engineered machinery was an important link in the chain of development of the industry. This task w a s made more difficult by the need to incorporate in the designs, the most recent innovations from the researchers and mill staffs.
With a perishable crop to be handled, lost time from breakdowns needed to be kept to a minimum, so reliability was an essential feature.
SUMMARY OF THE SUCCESS STORY.
In the preceeding paragraphs the story of the progression of mechanical engineering in the Australian sugar industry has indicated the following reasons for success. Firstly, the mill people, with vision and conviction championed the need for co-operative research and backed it with their funding through good times and bad; they set up the Sugar Research Institute with no government assistance, and that industry support has not wavered. Secondly, the researchers in the sugar
industry together with those from institutions of higher education, CSIRO and industry in general, co-operated readily in providing the unimpeded flow of information. Thirdly, the engineers in the mills recognised the value of the researchers' work and included those innovations, with some of their own, in a never-ending striving to improve the performance of the plant. They provided the feedback to the researchers and made the innovations work. They sought collaboration with SRI on all major engineering decisions and had free
interchange of information with other engineers throughout the Australian sugar industry.
ENGINEERING EDUCATION.
All undergraduates, academics and practising engineers recognise that the activities of an engineer graduating in a specific discipline will not be confined to that circumscribed area of engineering. I favour a broadly-based curriculum which has one or two technical subjects treated in depth. At the expense of limiting the depth of treatment of some of the other engineering topics I would include some brief treatment of general
importance to a graduate. A brief course on
business finance for undergraduates would help in removing the attitude to engineers which prevails, that technical boffins don't understand anything about finance or profitability and should not be promoted into positions of administraiton. In spite of this attitude some do finish up in the most senior positions and are successful. Short post-graduate courses should be readily available, but should be offered only at those higher education institutions which have the expertise to provide instruction in those special skills. In the policy discussion paper on Higher Education, issued in December 1987 by the Commonwealth Minister for Bmployment, Education and Training,
indications are that this will probably happen. It is vital to the success of our industries that they give wholehearted support to the courses which are directly relevant.
My greatest criticism of our graduates, who are very well prepared and have many engineering skills, is that they do not properly set about the task of identifying the problem. They are inclined to make some assumptions, then, with the aid of a computer, hurry on to do a fine piece of analytical work which is of little consequence. Quite often they show ingenuity in finding solutions for remedying the consequences of a problem without seeking to find the source of the problem.
Experienced engineers recognise that often it is identifying the problem which requires the major effort. The solution may then be very simple - or it may be clear that a complete re-design is necessary.
Many engineering students are not good mathematicians. They just manage to follow the work and look for a computer programme to solve the problems; when I was a student many looked with favour on the graphical solutions. Our courses need to b e , and many are, presented in a manner which enables physical concepts to be understood, progressively, rather than be presented in the form of a rigorous mathematical treatment yielding a large, complicated, general equation which may be used in an abbreviated form for specific cases provided the student knows what is going on. For the bright student this is a logical and economical use of time; for the ordinary fellow it is a major hurdle to be by-passed if possible. James W a t t , a clever instrument maker, wasn't a mathematical genius, but he was a creative thinker, an innovator of renown and a good engineer. We can't afford to lose any James Watts in our system.
We are all in the 'people business'. No matter how brilliant an engineer may become, if he is to be a success he must be able to handle personal relationship problems and be able to see the points of view of the employees, the public and the employer. A few sessions on this subject would benefit the undergraduate. I had the good fortune, as an apprentice and a nobody, to move freely among different tradesmen, and groups of varying interests. They had wide-ranging attitudes to life, the boss and to their fellow workers. It was an experience of lifelong value.
CONCLUSION
An apprentice, I soon found Great delight in moving 'round, Watching people and digesting what they said;
Then at uni. it was clear, That a new course I must steer, Less use of hand, more use of mind instead.
Lecturing gave satisfaction, But I felt the call for action, So to industry I turned, to have a try;
A post was offered me In the sugar industry,
At the Sugar Research Institute, Mackay.
Research was so inviting, The action was exciting,
So for five and twenty years I chose to stay;
With good staff I was blessed, They scored, passed every test, With industry-wide backing all the way.
We were helped throughout the nation, Groups from Higher Education, From C S . l . R . O . , and industry;
All the milling engineers Welcomed us, and showed no fears, In trying new ideas, as all can see.
Inspiration sets the pace, Perspiration wins the race,
In all of this, we found, good teamwork shares;
Now this medal I'll receive, As a tribute, I believe,
To my colleagues, for the honour's really theirs.
My successor as Director of SRI, Dr. Warren Gellie, formerly of CSIRO's Division of Manufacturing Technology, established in that Division an integrated manufacturing programne with research projects including robotics, industrial lasers, simulation and computer aided design. With this background it is anticipated that he will lead the sugar industry into a new era of innovation;
already, trials are being undertaken using a robot on cane juice sampling and analysis.
1 look forward to the future prosperity of the Australian sugar industry and, in particular, to the continued success of the Sugar Research Institute.
REFERENCES.
(1) MICHELL, A.G.M. (1942). Further Developments in Film Lubricated Bearings. Jour. I.E. Aust., Vol. 14, pp. 249-51.
(2) ANDERSON, C.N. and STALKER, R.J. (1981).
Technology Change in the Australian Sugar Industry.
Proc. Aust. Soc. Sugar Cane Technologists, pp. 7-
(3) M A W , P. and WRIGHT, D. (1983). Large Capacity Crushing Mill. Proc. Aust. Soc. Sugar Cane Technologists, pp. 273-279.
(4) S H W , M. (1969). The Research Work of G.E.
Russell. Proc. Qld. Soc. Sugar Cane Technologists.
pp. 357-366.
(5) HILL, J.W. (1969). Calandria Pan Studies.
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