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GOAL: Develop system concepts for automated manufacturing with high performance based on integration and adaptivity in manufacturing systems. RA1: Advanced Manufacturing Technology. WP1 – Robust and Adaptive Manufacturing Systems. WP3 - Hybrid Manufacturing.

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Presentation Transcript
slide1

GOAL:

  • Develop system concepts for automated manufacturing with high performance based on integration and adaptivity in manufacturing systems

RA1: Advanced Manufacturing Technology

  • WP1 – Robust and Adaptive Manufacturing Systems
  • WP3 - Hybrid Manufacturing
  • WP2 - Advanced Process Control and Intelligent Maintenance
  • GOAL:
  • Develop knowledge, tools, and concepts for advanced process control and intelligent predictive maintenance of equipment for high performance manufacturing
  • GOAL:
  • Develop the concept and principles for a hybrid manufacturing system
slide2

Collaboration between WPs

  • WP1 - Robust and Adaptive Manufacturing Systems

WP4

Planning and Control

Research area 1:

Advanced Manufacturing Technology

WP5

  • WP3 - Hybrid Manufacturing
  • WP2 - Advanced Process Control
  • and Intelligent Maintenance

Work Organization

T2

T3

WP6

T5

T4

slide3

PhD involvement

Task in all WP's: International collaboration and network building

slide5

Results from RA1WP1 Robust and Adaptive Manufacturing Systems

Control logic verification

Before

Now

Programming logic

in QUEST* syntax

'Verified' control logic

Programming logic

in target language** syntax

Truly verified control logic

in real equipment environment

*QUEST simulation software

**Python

slide6

Results from RA1WP1 Robust and Adaptive Manufacturing Systems

Control logic verification

Now

Programming logic

in target language** syntax

Truly verified control logic in

emulated equipment environment

Switching to real

equipment environment

slide7

Results from RA 1WP2 Advanced Process Control and Predictive Maintenance

  • Flexible, automated sewingfurther developed:
    • A software has been developed for integration of control of robot, PyMoCo and ROS
    • Real time control has been tested and promising results have been achieved for 8 milliseconds control.
    • A new speed sensor (mechanics and electronics) has been developed. The sensor will be used for measurements required for further development of the control system for the sewing cell.
    • Sew together parts of different shapes and materials, without prior knowledge of the part geometries
  • A predictive maintenance model has been established in order to obtain optimal maintenance scheduling based on the condition of the equipment.
  • RFID techniques in condition monitoring has been researched, and a demo of RFID application in production system has been established.
  • A dual arm robot installation is being built
slide8

Results from RA 1WP3 Hybrid Manufacturing

  • A new method for preparing the substrates for additive manufacturing in a CNC milling machine has been developed.
  • The cohesion of the AM section to the base part has been tested with excellent results (Marlok C1650+ CL 50WS AM tool steel).
  • Porous sections built into the tool insert derived as a valuable complement to other practical solutions
  • A prototype integrated control system for the hybrid cell (OMOS) has been further developed, in collaboration with exchange student from Slovenia.
  • A prototype of the hybrid cell control system has been developed.
other results
Otherresults
  • New projects:
  • Autoflex- Flexible automated manufacturing of large and complex products: Partners: Rolls-Royce Marine AS, BentelerAluminium Systems Norway AS, Intek Engineering AS, SINTEF Raufoss Manufacturing AS and NTNU.
  • SmartTools: Partners: Sandvik TeenessAS, SINTEF ICT, SINTEF Raufoss Manufacturing and NTNU IPK
  • Contribution to education:
  • The Framework of IFDPS becomes a part of a course (TPK 4155 Applied Computational Intelligence in Intelligent Manufacturing)
  • The RFID application demo for Production System becomes a practice study for a course called PK8106 Knowledge Discovery and Data Mining
international collaboration within ra1 in 2012
International collaborationwithin RA1 in 2012:
  • Chairman from Industry for Joining Sub-Platform: SFI Norman and SINTEF Raufoss Manufacturing AS have worked actively in Manufuture by participating in the HLG. As a result KristianMartinsen now holds the chair, as an industry representative, for the new sub-platform for Joining.
  • Exchange agreement with four students from Ensiame Engineering School, Valenciennes, France. Have been working on design of a flexible jig for assembly of components for Sandvik Teenessand a dual arm robot installation.
  • Collaboration through the development of the new ISO standard on additive manufacturing technology does now include the chair for ISO/TC261 WG1 Terminology for additive manufacturing.
  • DTI (Denmark), VTT (Finland), Acreo (Sweden), Fraunhofer (Germany): collaboration on coatings, integrated sensors and new business models for injection molding industry.
  • Two new EU-projects have been granted, SASAM and Diginova, where SINTEF Raufoss Manufacturing is a partner. Diginova, short for Innovation for Digital Fabrication, is a coordination and support action project under NMP 7th FP, Networking of materials laboratories and innovation. SASAM, which is short for Support Action for Standardisation in Additive Manufacturing, is a similar type of project.
  • Collaboration on a EU-proposal "VITAMIN", where Sandvik Teeness was partner together with SRM and SINTEF ICT from Norway. Not granted.
planned international collaboration within ra1 for 2013
Plannedinternationalcollaborationwithin RA1 for 2013:
  • PolytechnicInstituteofBraganca, Portugal:
  • Prof. Paulo Leitaõ: workshop aroundholonicmanufacturing, commonpublication or similar.
  • The University of Manchester, UK: Dr. Yi Wang:
  • establishing projects on Intelligent systems and Predictive Maintenance.
  • Common publication: a book on data mining for zero-defect manufacturing
  • VTT Technical Research Centre of Finland, +rest of consortium
  • EU proposal for call FoF.NMP.2013-7 "New hybrid production systems in advanced factory environments based on new human-robot interactive cooperation":
  • University of Ljubljana:
  • Prof. SlavkoDolinsek and student David Homar, continue collaboration on development on OMOS (Optimized Manufacturing Operation Sequence)
  • UniversityofBerlin (???? ):
  • Prof. Günther Seliger: workshop aroundflexibleautomation and possiblyresearcherexchange?
slide13

Some results from RA1

Substrate preparation

  • Flat milling produces a glossy surface;
    • Low-friction for powder spreading
    • Reflective to laser beam
  • Standard procedure: Sand blasting, -unsuitable for the hybrid cell
  • Hybrid cell procedure: Extra sharp cutting tool inserts "scratch" the substrate
    • Provides an exact z = 0 -point for starting the AM building
  • Edge radius: 0 – 0.1 mm;
  • Cutting depth: 0.1 mm;
  • Feed rate: 0.05 mm/O
slide15

Some results from RA1

WP3: Industrial case studies: insert for a bracket to an office chair

  • Results:
  • Cooling time for conventional insert and “old” design 70 sec.
    • Estimated cooling time with new design approximately +25 sec. = 95 sec.
  • Cooling time with new design and conformal cooling insert: 48 sec.
  • Cost of machining AM produced insert similar to conventional production, however the cost of AM makes this an expensive insert
  • Industrial need: reduced cost of production by AM closer to final shape
slide16

Demonstrator development

Working principle:

slide17

Demonstrator development

  • Example:
  • System Frame of IFDPS – Intelligent Fault Diagnosis and Prognosis System