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TITLE OF PAPER
AFIL - Associazione Fabbrica Intelligente Lombardia
The Vanguard Initiative: an opportunity for manufacturing companies to exploit network of pilot plants to validate high-risk investments in efficient and sustainable manufacturing
In the frame of the initiative “Vanguard – New Growth Through Smart Specialization”, AFIL together with EURECAT is coordinating the “ESM – Efficient and Sustainable Manufacturing” pilot project with the intent of conceiving and developing a European networked infrastructure of pilot plants in key-areas of manufacturing. By leveraging available research results, ESM European pilot plants will support companies’ innovation in breakthrough technologies and applications that require manufacturing efficiency and sustainability. This approach will generate European competitive value chains exploiting synergies and complementarities of different regional specialization in the framework of circular economy, intelligent and digital factory, energy efficiency and sustainable materials.
Rapid reconfiguration of flexible production systems
Marcello Colledani, Politecnico di Milano - Dipartimento di Meccanica | Giovanni Paolo Borzi, EnginSoft SpA
A novel capability-based approach is presented, enabling to design production systems from mechatronic objects and to adapt production systems capabilities based on the workpiece requirements.
This approach facilitates the automatic matching between workpiece requirements and resource capabilities, therefore enabling two important phases: new production system designs (green-field design phase) and online reconfiguration management of operational systems (i.e., production and reconfiguration planning). Moreover, it provides the basis for the auto-programming of the mechatronic objects for required tasks, therefore enabling rapid reconfiguration of the system according to product requirements.
The developments support the integrated design and operation of future production systems that allow quick, cost-efficient set-up and the fast integration of new product variants.
This full presentation is not available
Reliability Growth model for a diode laser-based tape winding machine
Angelo Merlo, Mach4Lab srl | Martin Schäkel, Fraunhofer - Institute for Production Technology (IPT) | Tido Peters, Fraunhofer - Institute for Production Technology (IPT) | Francesco Aggogeri, Mach4Lab srl
Considering the key role played by maintenance related costs in the operative life of machine tools, Reliability issues must be addressed starting from the very beginning of the system design. In this framework is here proposed a statistical model, based on Reliability Growth Analysis, aimed at improve the mean life of the system components. This kind of analysis is no common practice in machinery and the model here proposed is applied to a laser-based tape winding machine, currently at prototype stage. Failure data, collected according to a systematic procedure during the machine test-find-fix-test trials, are analyzed using Reliasoft Synthesis Platform according to a Crown/AMSAA based extended model. Actual and projected Mean Time Between Failures (MTBF) are calculated through simulations of various scenarios and the Growth Potential of the system is assessed. Improvements based on reasonable effectiveness factors are suggested to increase reliability performances of the machine.
An innovative approach to design optimization of production lines under regional requirements
This work describes a novel approach to the preliminary design of production systems aimed at satisfying the global growing demand for high volum+A1:R71e manufacturing systems. The approach presented in the talk combines Knowledge Based Engineering tools with modelling and optimization techniques. The resulting technology offers an integrated approach to fast and first-time-right production systems design, capable of taking into account engineering constraints, efficiency and reliability KPIs, equipment costs, and region-dependent parameters such as local energy costs, personnel costs etc.
AR4CAD, a CAD-based framework for the creation of assembly assistants that make use of augmented reality
AR4CAD makes use of the CAD description of a complex object and of CAD tools to support the efficient design of the storyboard of the virtual assembly of that object; then, starting from this storyboard, a specific assembly assistant, based on augmented reality (AR) techniques, is automatically generated.
The assistant supports the operator during the assembly by:
• guiding him through the appropriate sequence of steps of the process;
• recognizing the individual objects being handled (without the need of specific markers) and eventually checking their size;
• providing the information required to mount component parts in the right place and position. This is done primarily by properly overlaying virtual companion parts aside the image of an anchor object being captured by the camera or by overlaying a completely virtual assembly animation over this same anchor;
• verifying (to some extent) that assembly steps are performed correctly.
The system, developed so far in prototype form, makes use of a camera observing the work space (in practice a table). An additional camera located at a known distance from the bench surface is used for precise measurements.
Simulations and experimental results on work machines in the digital twin era
Some experiences with work machines will be presented concerning data acquisition for continuous monitoring of manufacturing processes where experimental measurements may help to understand process efficiency, product quality and the correctness of simulation models.
Vibrational analysis for existing working machines points out some critical issues related to the data acquisition from the field while a distributed monitoring architecture based on CLOUD and edge-computing, together with control instruments and feedback capability towards machineries, may represent a major advantage.
The presentation ends by highlighting some benefits this approach can bring within the INDUSTRY 4.0 and in particular the requirements’ compliant for the fiscal benefit related to the Italian market.
Additive Manufacturing (AM) technologies would undoubtedly help meeting new and competitive industrial needs, such as production of lightweight and customized components. New methodologies of Design for Additive Manufacturing (DfAM) and relative CAx tools are the key enabling technologies allowing to get the major benefits from these advanced technologies. The current tendency by software developers is to preserve their main purpose while adding features for AM. Nonetheless, it is more and more evident that an increased integration would lead to a more efficient design and engineering workflow.
In this paper, a novel integrated platform for AM design is proposed, and results of a workflow based on it are illustrated. Starting from geometrical, functional and structural product specifications, the platform includes a topological optimization phase, new geometry construction, automatic FEM discretization. After FEA validation of the new geometry, optimal orientation is found and supports are created related to the component. The presented platform is the first step towards a fully integrated product & process design & engineering workflow.
The exponential increase of volume of data represents a great opportunity in the Industry 4.0 but a common mistake is consider this Fourth Revolution only as the injection and digestion of Tons of data useful during production phase. This data revolution has an unexplored potential for what concern the full lifecycle of the products too. Especially for what concern maintenance, great possibilities are lying ahead for a revolutionary way to plan, do and predict maintenance, based on the same data used during production. But it's not enough because it's necessary to introduce in this equation the human role that it's another key factor to consider. During production, quality control or maintenace processes, the human intervention must constantly supported and tracked in real time to have the complete control of the process. This integration is the goal of our system that combine data coming from machine and technicians on field, to make a real quantum leap in this scenario.