NEXT GENERATION PRODUCTION SYSTEMS:  NEXT

NEXT GENERATION PRODUCTION SYSTEMS: NEXT PowerPoint PPT Presentation


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NEXT IP 011815. 2. OVERVIEW OF NEXT PROJECT. NEXT IP 011815. 3. . OBJECTIVES. NEXT IP 011815. 4. OVERVIEW OF NEXT PROJECT. NEXT IP 011815. 5. CRITICAL MASS MERGED 6 EXPRESSIONS OF INTEREST OF FP6 23 PARTNERS FROM 9 COUNTRIES PARTNERS REPRESENT THE COMPLETE

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NEXT GENERATION PRODUCTION SYSTEMS: NEXT

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1. 1 NEXT GENERATION PRODUCTION SYSTEMS: NEXT Start date: End date: 01 September 2005 31 October 2009 Duration: 4 years Budget: 21,745,801 € EC contribution: 13,999,999 €

2. NEXT IP 011815 2 OVERVIEW OF NEXT PROJECT

3. NEXT IP 011815 3 OBJECTIVES

4. NEXT IP 011815 4 OVERVIEW OF NEXT PROJECT

5. NEXT IP 011815 5 CONSORTIUM

6. NEXT IP 011815 6 EXPECTED MACRO END RESULTS

7. NEXT IP 011815 7

8. 8 TRACK1: GREEN MACHINES Radical innovation into environmentally friendly production machines. Consider environmental aspects through the entire life-cycle of machines: use of recycled materials for machine elements, reduction of energy consumption at machine use, zero waste produced, dismantling and recycling of 100% machines, and working in non-pollutant machining processes.

9. NEXT IP 011815 9 GRINDING Demonstrator EDD EDD (Electro Discharge Dressing). Metallic bonded wheels dressed in the machine BENEFITS Power consumption reduced up to 30% thanks to the increased grain exposure in the wheel. Possibility to dress metallic superabrasive wheels in the own machine with medium values of grain size ? more precision Lower piece cost because the life of the wheel is increased up to 40%. Tool life will be compared to machine life. Applications for hard metal grinding; any application of peeling

10. NEXT IP 011815 10 GRINDING Demonstrator MQL MQL in grinding BENEFITS Energy consumption reduced up to 50 %. Liquid power pumps are eliminated. Less space occupied by the machine, up to 50 % . Production costs reduced because the machine is cheaper (less space needed) and power consumption reduced. No liquid residues are produced

11. NEXT IP 011815 11 ONA Demonstrator (WEDM) Development of high technological WEDM with better environmental behavior INNOVATIONS Improve the Paper Cartridge filter lifetime using a secondary filter washable module Development of Washable filter suitable to treat higher amount of residues (high speed of 300 mm2/min possible)of WEDM machine with integrated high speed cutting generator. Reduce the conductivity of the water dielectric fluid by flowing it through the resins interchange stage. Resin consumption reduction BENEFITS New filtration units will allow reducing the waste generation up to 50%

12. NEXT IP 011815 12 Study the usage phase of the machine The result of the LCA performed to a machine tool shows that the use stage is the stage that has more environmental impact. The use stage includes the power consumption to turn on the machine, to move the mobile components and to performe the process and the consumables themselves. The result of the LCA performed to a machine tool shows that the use stage is the stage that has more environmental impact. The use stage includes the power consumption to turn on the machine, to move the mobile components and to performe the process and the consumables themselves.

13. 13 TRACK 2: USER-CENTRIC AUTONOMOUS MACHINE Establishing the base of a new generation of autonomous and “user-friendly” machines that will support a much more efficient and comfortable way of working (e.g. automatic recognition of manufacturing tasks and process conditions).

14. NEXT IP 011815 14 EMCO E900 / CORREA RELEVANT INNOVATIONS Automated identification of friction and acceleration behaviour using trace functionality and Extended Trace Capability Implementation of faster setup and calibration services Integration of machine model within tool path planning (? machining time up to 50%) Implementation of an adaptive control that allows monitoring the surface roughness online Implementation of a CUTOPT model-based surface roughness monitoring in milling operations Implementation of an indirect thermal compensation Implementation of a wear detection software for guide ways

15. NEXT IP 011815 15 EMCO E900 / CORREA BENEFITS More reliable manufacturing processes Higher accuracy of produced goods Reduction of reject rate Reduction of production costs Less maintenance services

16. NEXT IP 011815 16 Gun Drilling Demonstrator The demonstrator consists of an adaptive control system which is enriched by technological knowledge about the process and tool behaviour gained by simulation The demonstrator consists of an adaptive control system which is enriched by technological knowledge about the process and tool behaviour gained by simulation

17. NEXT IP 011815 17 Gun Drilling Demonstrator BENEFITS The use of an adaptive control in gun drilling allows increasing the productivity and the process reliability. As process behavior changes significantly during manufacturing, and adaptation of controller parameters is essential to achieve the optimum in performance. The objective is to machine at the tool’s load limit. For Bosch large scale injector pipe manufacturing is the main field of application while CRF is mainly interested in drilling crankshafts The simulation contributes a quick analysis of tool load limits whithout raising test costs. The availability of production machines increases as initial tool tests can be reduced or generally avoided.

18. 18 TRACK 3: THE MANUFACTURING BREAKTHROUGH Designing and building the best process-controlled production machines in the world in terms of performance, productivity and achievable quality (2x - 5x improvement in machine tool productivity, increasing accuracy, higher reliability).

19. NEXT IP 011815 19 High Speed Milling Machine for dies&moulds machining – FIDIA Aluminum Foam FOAM Very light, stiff and intrinsically damped material/structure for the moving parts of machine tools, in order to damp low frequency structural vibrations. Technologies investigated: low cost CFRP manufacturing, Sandwich with cellular metal core (filled in with syntactic low density foams); Low cost tubolar Sandwich with Al foams, ultralight Mg alloy Al-foam structures Tests on demonstrator equipped with conventional and CFRP RAM have been carried out Al-foam RAMs have been manufactured Final machining needed in order to perform bench and machining tests Embedding fibres into structures Fibers have been embedded into the RAM Reference bench tests on conventional and CFRP RAMs have been performed Reference machining tests on CFRP RAM are in progress Aluminum Foam FOAM Very light, stiff and intrinsically damped material/structure for the moving parts of machine tools, in order to damp low frequency structural vibrations. Technologies investigated: low cost CFRP manufacturing, Sandwich with cellular metal core (filled in with syntactic low density foams); Low cost tubolar Sandwich with Al foams, ultralight Mg alloy Al-foam structures Tests on demonstrator equipped with conventional and CFRP RAM have been carried out Al-foam RAMs have been manufactured Final machining needed in order to perform bench and machining tests Embedding fibres into structures Fibers have been embedded into the RAM Reference bench tests on conventional and CFRP RAMs have been performed Reference machining tests on CFRP RAM are in progress

20. NEXT IP 011815 20 High Speed Milling Machine for dies&moulds machining – FIDIA BENEFITS Improvement in productivity of about 10% is the target related to the implementation of knowledge and process-related algorithms in an open architecture framework , contributing with a 4% revenue increment in selling CNC (over 300.000 € in two years) Improvement in performance of about 10-15% by using light weight ram (Al-foam, CFRP) with a ram cost increase of 30% (2.000 € against 1.500 €) Improvement in performance of about 20% by implementing a thermal compensation system based on FBG’s with a ram cost increase of 50% (fibers + reading unit) (machine cost increase of 5-7%) The implementation of innovative and easy-to-apply methods will allow for performing ECO-impact analysis on machine tools with time and costs which are suitable and tailored to such application The implementation of knowledge and process-related algorithms in an open architecture framework represents a competitive advantage against conventional CNCs Improvement in productivity of about 10% is the target related to the implementation of knowledge and process-related algorithms in an open architecture framework , contributing with a 4% revenue increment in selling CNC (over 300.000 € in two years) Implementing innovative and smart materials in machine tools keeping down costs represents an exploitation-oriented research approach which allows for overcome actual application limits Once industrialized, performance improvement in the range of 10-15% with a RAM cost increase of 30% (2.000 € against 1.500 € of conventional RAM) Once industrialized, performance improvement in the range of 20% with a cost increase of 50% (fibers+reading unit) will be acceptable, as long as customers are ready to pay 5-7% more for having problem solved The implementation of innovative and easy-to-apply methods will allow for performing ECO-impact analysis on machine tools with time and costs which are suitable and tailored to such application The implementation of knowledge and process-related algorithms in an open architecture framework represents a competitive advantage against conventional CNCs Improvement in productivity of about 10% is the target related to the implementation of knowledge and process-related algorithms in an open architecture framework , contributing with a 4% revenue increment in selling CNC (over 300.000 € in two years) Implementing innovative and smart materials in machine tools keeping down costs represents an exploitation-oriented research approach which allows for overcome actual application limits Once industrialized, performance improvement in the range of 10-15% with a RAM cost increase of 30% (2.000 € against 1.500 € of conventional RAM) Once industrialized, performance improvement in the range of 20% with a cost increase of 50% (fibers+reading unit) will be acceptable, as long as customers are ready to pay 5-7% more for having problem solved The implementation of innovative and easy-to-apply methods will allow for performing ECO-impact analysis on machine tools with time and costs which are suitable and tailored to such application

21. NEXT IP 011815 21 Agile Machining Centre for Prismatic Components - MAG INNOVATIONS Modular design: Configurability of wide range of machine variants by using a smaller number of common modules and components Model based temperature compensation in order to avoid the loss of accuracy caused by thermal influences Compile cycles for advanced control in order to get exact and fast positioning of heavy mass Set-up and calibration service in order to decrease the setup time of a 5 axis machine Energy saving program Optimization of high performance cutting

22. NEXT IP 011815 22 Agile Machining Centre for Prismatic Components - MAG BENEFITS Reduced investment costs Reduced warm up time and increased accuracy Faster and more exact positioning Faster set-up time Increase material removal rate

23. 23 TRACK 4: Economic objective New ways of doing business in the production machinery sector. Exploring and defining new ways of selling products AND services, new formulae not currently applied related to ownership of the equipment, payment, financing, new organisation models, etc..

24. NEXT IP 011815 24 New business models

25. NEXT IP 011815 25 New business models INNOVATIONS Consultancy methods, contents and tool for business model innovation of manufacturing companies Business model life cycle assesment software Technical configurator

26. NEXT IP 011815 26 New business models BENEFITS Consultancy methods, contents and tool for business model innovation of manufacturing companies They enable high-level consulting in the fields of customer-oriented business model selection and in adapting organizational structures to the newly arising requirements will be offered to machine tool building companies Clear and structured methodology for strategic innovation Decision support systems to assist strategic decisions: a)Cooperation scenarios preliminary selector; b) Financial guidelines; c) Organizational guidelines

27. NEXT IP 011815 27 New business models BENEFITS Business model life cycle assesment software Evaluation of the economical and environmental performances deriving from the adoption of an innovative business model with respect to the actual one. It permits to quantitatively evaluate the impact of innovative cooperation options between supplier and customer/business partners and of unconventional financial models. Focus not only on machine tool, but on the whole production system Customer/supplier win-win situations for the competitiveness of the whole manufacturing system and not only of some of its actors

28. NEXT IP 011815 28 New business models BENEFITS Technical configurator Supports the search, selection and configuration of machine tools and manufacturing systems, calculates system attributes (e.g. cost, space occupation, MTBF, MTTR) needed by LCA, and visualizes the 3D models of the configured machinery. Allows more efficiency in offers preparation, a higher probability of their success,and a professional technical-commercial approach that will attract customers. Customers will be more involved during the definition of the manufacturing system that should fulfill their industrial need. They will have the opportunity to consider technical aspects in advance and to make a better choice. More than one technical alternatives will be configured and evaluated, so that the guarantee that the system will be effective will be higher.

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