ICRA Industry 4.1 for Wheel Machining Automation. Spotlights. Fan-Tien Cheng. e-manufacturing Research Center National Cheng Kung University

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1 ICRA 2016 Industry 4.1 for Wheel Machining Automation Spotlights Fan-Tien Cheng e-manufacturing Research Center National Cheng Kung University May 18,

2 Industry 4.0 Industry 4.0 = IoT + CPS + Cloud Manufacturing (CM) + Big Data Analytics. Industry 4.0 only keeps the faith of achieving nearly Zero Defects (ZD) state. Zero Defects (ZD) ZD has been one of the quality-improvement objectives for accomplishing manufacturing quality [1]. Through prevention methods, ZD aims to boost production and minimize waste. ZD is based on the concept that the amount of mistakes a worker makes doesn't matter since inspectors will catch them before they reach the customer [1]. [1] Halpin, James F. Zero Defects: A New Dimension in Quality Assurance, New York: McGraw-Hill,

3 Prediction Qualuty Measurement Quality Workpiece VM for Machine Tools Off- Machine Measuring 3 On- Machine Measuring (2) (1) Sampling Real Measurement Data Coordinate Measuring UCL (3) Sensor Data & Process Data Virtual Metrology System Real-Time & On-Line Measurement TimeΔT Sampling Data at t Virtual Metrology Data LCL UCL LCL Sampling Data at t VM can convert sampling inspections with metrology delay into real-time and on-line total inspection.

4 Purpose 4 The purpose of this paper is to propose a platform denoted Advanced Manufacturing Cloud of Things (AMCoT) to not only achieve the objectives of Industry 4.0 but also accomplish the goal of Zero Defects by applying the technology of Automatic Virtual Metrology (AVM).

5 Industry 4.1 Industry AVM = Industry 4.1 To achieve the goal of Zero Defects Stage I:Achieving the goal of Zero Defects for all the Deliverables Stage II:Achieving the goal of nearly Zero Defects for all the Products (by Big Data Analytics & Continuous Improvement) 5

6 Integrating GAVM into Wheel Machining Automation for Total Inspection (1/3) The Wheel Machining Automation (WMA) cell layout AVM Server two lathes (Lathe 1 and Lathe 2) one drilling machine (Drill) one off-machine metrology (OMM) tool for sampling inspection of all precision items one robot is placed in the middle of the cell for material handling and two buffers are installed for input/output purposes. Lathe 1 Reader In Drill Out Laser Marker Lathe 2 OMM GED 6

7 Integrating GAVM into Wheel Machining Automation for Total Inspection (2/3) GED Turns GED to CPA AVM Server Machine Tool Metrology Tool Sensor Data Metrology Data Machining Parameter Interface Box Pluggable Application Module (PAM) EquipmentDriver DCReport DataCollection Manager ApplicationInterface DCPlan CommunicationAgent Process Data STDB Metrology Data DQIx DQIy Z-Score Data Preprocessing Z-Score Data Preprocessing Only for Training & Tuning Conjecture Model Advanced Dual-Phase VM Algorithm RI Module GSI Module VM I VM II RI GSI GAVM system for machine tools. 7

8 Integrating GAVM into Wheel Machining Automation for Total Inspection (3/3) Integrate GAVM into WMA: a Miniature of Industry 4.0 GED is the prototype of an IoT agent AVM is an example of CPS To Do: Enhance the functions of GED, and then adopt Advanced Manufacturing Cloud of Things (AMCoT) for wheel production industries based on the miniature GAVM system. 8

9 Advanced Manufacturing Cloud of Things AMCoT provides a cloud-based platform for connecting and sharing all information of things for bridging the technology supports among vender, customers, and manufacturing tools. AMCoT Customer 4 Vender Customer 3 Customer 2 Customer 1 One-to-Many Relationship among a Vender and its Customers via AMCoT Application Example -- AVM Model-refreshing: Each customer does not need to build its own AVM models but just downloads all the preliminary AVM models (provided by the vender) from AMCoT. 9

10 Applying AMCoT to WMA AMCoT Customer 4 STDB/ CDB AVM System Collision Detection Service Intelligent Predictive Maintenance Metrology Planning Service Tool Life Management Service Customer 3 Customer 2 Vender Customer 1 CPA Cell 1 Tool CPA 1 Cell 2 RUL CPA 2 Integrating WMA s Vender and Customers into AMCoT 10

11 Reference F.-T. Cheng, H. Tieng, H.-C. Yang, M.-H. Hung, Y.-C. Lin, C.-F. Wei, and Z.- Y. Shieh, Industry 4.1 for Wheel Machining Automation, IEEE Robotics and Automation Letters, vol. 1, no.1, pp , January