Fraunhofer Institute for production systems and Design technology ipk. Digitally Integrated. Fraunhofer IPK at. April 24 28, Hall 17, Stand C18

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1 Fraunhofer Institute for production systems and Design technology ipk Digitally Integrated Fraunhofer IPK at Production Hannover Messe 2017 Hall 17, Stand C18 April 24 28, 2017

2 Introduction 3 Exhibits 6 Our Services 12 Location at the Fair 14 Contact / Imprint ,5 8,5 952º 1040º 965º 1 040º 940º 840º 2

3 in di vi du al adjective, from the French; [1] relating to single persons or objects, [2] customized, made with individuality in mind, concerning personality Get going A tendency towards custom products»off the peg«was yesterday. Today, many enterprises execute custom processes for every client or even every single order often with annual repetition rates of 1.3. Letting buyers choose the color or styles of custom trainers or designing custom car interiors are no major problem. System suppliers regularly face completely different challenges: Their clients order components made from materials they have never used before or require certifications that their standard production processes were not designed to accommodate. Spanners in the works Such special requests are a tough test for the economic viability of production processes. The problem is simple: They take time. Mass production is designed to function like a Swiss clockwork: An order is received, and everybody knows what needs to be done. From initial logistics down to the finishing touch, every process step is intricately linked with the next to keep the entire process running smoothly. This is far from straightforward with custom orders, which require much more coordination. A change in the raw materials needs careful checks whether the available machines can process the material, where the material can be procured, and how to proceed in general when it is not predetermined who does what at which point. This makes custom products much more expensive than mass production. End of the line for the production line The many advantages of customized products let clients accept greater costs to some extent but truly flexible manufacturing can only become economically sustainable, if it is faster and cheaper than before. Throughput speeds and production costs need to hold their own with more established mass production. Is that possible? 3

4 Adaptation? Done! fle xi ble adjective, from the Latin; [1] pliant, elastic, [2] adapting to changing circumstances The solution: Digitally integrated production! Industrie 4.0 or digitally integrated production (dip) offers thousands of promising solutions for the challenge»speed up, costs down«. The spectrum of options reaches from pin-point interventions in existing systems to sweeping restructuring of entire process chains. However ambitious your plans to make your production faster and more flexible, Fraunhofer IPK will support every level of configuration with bespoke solutions. At Hannover Messe 2017, we are showing how this can work in practice HM 2017: We produce flexibility Production of plastic components can be quick and economical, even if key production parameters are changed, thanks to integrated modular product, production, and IT architectures, smart data, and cloudbased control systems. Novel technologies keep the entire process speedy and responsive: Modular Shopfloor IT combines manufacturing facilities flexibly in ever new process chains, ready to handle customized orders. This becomes even more responsive when the machine controls are moved into the cloud: All software is brought together in one place, for easier maintenance and the speedy integration of changes. Smart data transmits the data from production facilities into a digital twin that tests the feasibility of requested product or process changes without stopping production. The end result: Cheaper and faster manufacturing

5 Our Fair Exhibits Exhibit 1: Modular Shopfloor IT Complex IT architecture from simple building blocks Exhibit 2: Digital Twin Virtually validate product changes Exhibit 3: picasso Cloud-based robot control

6 Exhibit 1: Modular Shopfloor IT Further information: Find here: Project leaflet Modular Shopfloor IT (in German) Project leaflet Process Assistant (in German) Project leaflet Industrie 4.0 Suitcase (in German) Contact Dr.-Ing. Thomas Knothe Phone:

7 Mo dule, the noun, from the Latin; [1] (in electronics) replaceable complex element of a greater system, such as a device or machine that constitutes a separate functional unit Complex IT architecture from simple building blocks Customer request: Adapt products and processes! A company might be producing plastic components, thousands of items per day, in one constant configuration. The client now demands a change, smaller, thicker, thinner, made from a different material or as our fair exhibit shows individually labelled. Even such deceptively trivial changes will have repercussions on all levels of manufacturing, from the control room to the individual machine controls. So far, any changes to products or processes have to be programmed manually in all systems involved in the process. Time and quality constraints make such change requests an unpopular part of industrial life. Combining modules instead of reprogramming Modular Shopfloor IT facilitates such change requests enormously. It integrates with the machine controls and makes them available for remote management and integration with higher systems. Changes to processes are not communicated from person to person anymore, but through the IT system e.g. from order management directly to production. The software relies on a building block principle: Even if a factory uses machines of all different makes and types, the control and monitoring functions will be similar. That means that only few modules are needed to cover the entire value chain of any company. When the maker of plastic components receives a change request, the Shopfloor IT modules are recombined and the required production parameters are submitted directly. If a special dashboard as showcased at Hannover Messe 2015 and 2016 is added, process data for order-specific analyses can be accessed. In 2017, the complete system will, for the first time, be combined with a flexible performance board to connect live production data directly with possible optimizations. Your benefits Modular Shopfloor IT is a model example of simple, but effective solutions that are quick and easy to realize. They rely on existing technology taking away many of the concerns about Industrie 4.0 and making dip an appealing option even for SMEs. 7

8 Exhibit 2: Digital Twin N0001 (Post: Shapeoko3_GRBL) N0002 N0003 (2MM) N0004 G90 G21 G17 G94 N0005 (2MM) N0006 (CAVITY_MILL) N0007 G00 X0.0 Y0.0 Z0.0 S120 M03 N0008 X Y Z-23. N0009 G01 X Y Z-33.5 F2500. M08 N0010 G02 X Y I2.252 J F500. N0011 G02 X Y I7.78 J N0012 G02 X Y I J N0013 G02 X Y I J N0014 G01 X Y N0015 G03 X Y I.918 J-.396 N0016 G02 X Y I J Further information: Find here: Press information Industrie 4.0: Virtual Twin controls Production Project leaflet Digital Twin (in German) Contact Prof. Dr.-Ing. Rainer Stark Phone:

9 vir tu al adjective, from the French; [1] simulated by a computer, [2] theoretical, not actual, [3] unreal, not present in reality, but real in perception Virtually validate product changes Changing processes? A sure thing! The custom order has reached the production facilities directly. But can it be produced at all? Product developers need to make sure that e.g. the space for the requested label is sufficient and that no other conflict arises. All of these details can be checked with the digital twin, a virtual copy of production facilities. It not only reflects its geometry and layout, but also the actual behavior of the plant with the right level of detail for the application in question. can be used to influence actual production: If a virtual collision is provoked, the real-world counterpart of the system will halt. This can be used for preemptive monitoring: As long as the virtual twin is a few seconds ahead of the real production facilities, collisions can be avoided even without physical sensors. This is where smart data comes into play: With the data produced by the machines on the ground, the virtual production system can be constantly optimized. Versatile tool We are exhibiting a digital twin that is synchronized with a small-scale manufacturing demonstrator. Multiple sensors, both physical and virtual, track the operating state of the real production hardware and transfer it to the twin. The twin can model the production of product variants before they enter actual manufacturing or test whether and how new facilities could be integrated into the existing manufacturing processes. This allows quick verifying of product or facility changes. At the same time, the digital twin Our target group The exhibit is designed specifically with manufacturers and plant engineers in mind. We want to work with you to define scenarios that will benefit from the use of digital twins. As a next step, the use case will be defined to make sure that only such aspects of production processes are mirrored that will actually produce added value for your business. The scenarios will be prototyped to make the benefits of the twin tangible for its operator a key precondition for its implementation and acceptance on a greater scale. 9

10 Exhibit 3: picasso <PATH><XPOS Type="#N"><TCP_T Frame="$BASE"><x>9.27e+00</x><y>6.33e+02</y><z>4.62e+01</z></TCP_T> <TCP_R Frame="$BASE"><rx>180.0</rx><ry>0.0</ry><rz>7.65e+01</rz> </TCP_R><Teach_Tool_T><x>0.0</x><y>0.0</y><z>0.0</z></Teach_Tool_T><Teach_Tool_R><rx>0.0</rx><ry>0.0</ry><rz>0.0</rz></Teach_Tool_R></XPOS> <XPOS Type="#N"><TCP_T Frame="$BASE"><x>-3.63e-01</x><y>3.30e+02</y><z>3.32e+02</z></TCP_T><TCP_R Frame="$BASE"><rx>180.0</rx><ry>0.0</ry><rz>7.80e+01</rz></TCP_R> <Teach_Tool_T><x>0.0</x><y>0.0</y><z>0.0</z></Teach_Tool_T><Teach_Tool_R><rx>0.0</rx><ry>0.0</ry><rz>0.0</rz></Teach_Tool_R></XPOS> <XPOS Type="#N"><TCP_T Frame="$BASE"><x>3.24e+02</x><y>5.85e+01</y><z>3.32e+02</z></TCP_T> <TCP_R Frame="$BASE"><rx>180.0</rx><ry>0.0</ry><rz>0.0</rz></TCP_R> <Teach_Tool_T><x>0.0</x><y>0.0</y><z>0.0</z></Teach_Tool_T><Teach_Tool_R><rx>0.0</rx><ry>0.0</ry><rz>0.0</rz></Teach_Tool_R></XPOS> </PATH><PATH><XPOS Type="#N"><TCP_T Frame="$BASE"><x>6.07e+02</x><y>4.94e+01</y><z>1.95e+02</z></TCP_T><TCP_R Frame="$BASE"><rx>180.0</rx> <ry>0.0</ry><rz>0.0</rz></tcp_r> <Teach_Tool_T><x>0.0</x><y>0.0</y><z>0.0</z></Teach_Tool_T><Teach_Tool_R><rx>0.0</rx><ry>0.0</ry><rz>0.0</rz></Teach_Tool_R></XPOS> <XPOS Type="#N"><TCP_T Frame="$BASE"><x>4.94e+02</x><y>3.57e+02</y><z>3.15e+02</z></TCP_T><TCP_R Frame="$BASE"><rx>180.0</rx> <ry>0.0</ry><rz>2.94e+01</rz></tcp_r><teach_tool_t><x>0.0</x><y>0.0</y><z>0.0</z></teach_tool_t><teach_tool_r><rx>0.0</rx><ry>0.0</ry><rz>0.0</rz></teach_tool_r></xpos> <XPOS Type="#N"><TCP_T Frame="$BASE"><x>2.86e+00</x><y>6.11e+02</y><z>4.67e+01</z></TCP_T><TCP_R Frame="$BASE"><rx>180.0</rx><ry>0.0</ry><rz>8.33e+01</rz></TCP_R> <Teach_Tool_T><x>0.0</x><y>0.0</y><z>0.0</z></Teach_Tool_T><Teach_Tool_R><rx>0.0</rx> <ry>0.0</ry><rz>0.0</rz></teach_tool_r></xpos></path> Further information: Find here: Project leaflet picasso Project leaflet RetroNet Project leaflet EnEffReg (in German) Contact Dipl.-Ing. Moritz Chemnitz Phone:

11 Cloud, the noun, English; [1] Network of computers, online data storage and server services in the Web 2.0 Cloud-based robot control Giving customers what they ask After the digital twin has checked whether the product can be manufactured to the customer s specifications, it is handed over to actual production. At Hannover Messe, we are simulating this with a robot cell for palletizing. Saving costs in the network What makes the cell special is the fact that all of its components are designed as cyber-physical systems (CPS). The conveyor belt, camera, and robot are each handled by one service that is recorded in the»yellow Pages for Industrie 4.0«and readily available from anywhere in the world. In addition, there are purely virtual services, such as object recognition features used to identify grip points. When a component is delivered by the conveyor, the service will tell the camera to send an image to the object recognition service. The service tells the robot the exact grip point for the product. The clever feature: All services can be integrated for individual products every product can e.g. call up the right object recognition service. Such flexible service integration makes use of all advantages of cloud solutions: They are more economical because they require far less high-performance, high-cost hardware on site. Complex calculations are outsourced into the cloud, which is more responsive, as virtually unlimited computational power can be added at the point of need. It is more secure, because confidential data remains with its legitimate owner. And it makes maintenance easier, because all services are centralized. How does your business get into the cloud? We are available to help you implement cloud services and highly flexible integrated automation solutions at your business. 11

12 Cooperation, the noun, from the Latin; [1] Working together, especially in politics or industry Our proposal: Start dip! There are countless opportunities for using digitally integrated production dip to make even highly customized processes speedy and responsive. We can support you, from quick-win changes to the wholescale reorganization of entire manufacturing sites. Quick solution or comprehensive program? Small to medium-sized enterprises in particular benefit from targeted adjustments to their processes or facilities. Simple solutions, individual technologies, and specific procedural changes can be integrated with minimal effort, but promise maximum returns in terms of throughput speeds and production costs. However, digitally integrated production best realizes its potential by using a holistic approach. Technology only represents a minor part of Industrie 4.0. The vast majority lies in the reorganization of process flows to make the leap from linear to parallel processes. The right solution for your specific needs will lie somewhere along the continuum between both extremes. With our support, you will find the right concept for your journey towards digitally integrated production. Your introduction to Industrie 4.0 Our»Start dip«program offers comprehensive support for newcomers to the world of Industrie 4.0: Know what is possible: Information and training to get you ready for digital transformation. Status quo and requirements analyses: We will work with you to check how ready your company is for Industrie 4.0, which options are feasible, and which digitally integrated production scenarios are suitable for you. Prototypes for a»hands-on«experience are developed in short time to help you develop competences and to spread awareness in your workforce. Rollout support: We develop implementation strategies and support you in the step-by-step integration of the required processes and IT systems. Learning factories give your employees the competences they need for intelligent integrated manufacturing. Join us to find your path to digitally integrated production! 12

13 Further information: Find here: Project leaflet Digitally integrated Production Detailed information on our services and contact persons at our institute Contact Dipl.-Ing. Eckhard Hohwieler Phone:

14 Visit us: Hall 17, Stand 18C 14

15 ContaCt Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr Berlin Contact»Digitally integrated Production«: Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann Phone: eckart.uhlmann@ipk.fraunhofer.de Dipl.-Ing. Eckhard Hohwieler Phone: eckhard.hohwieler@ipk.fraunhofer.de Divisions involved Corporate Management Prof. Dr.-Ing. Holger Kohl Phone: holger.kohl@ipk.fraunhofer.de Virtual Product Creation Prof. Dr.-Ing. Rainer Stark Phone: rainer.stark@ipk.fraunhofer.de Automation Technology Prof. Dr.-Ing. Jörg Krüger Phone: joerg.krueger@ipk.fraunhofer.de Jeannette Baumgarten Phone: jeannette.baumgarten@ipk.fraunhofer.de Images Fraunhofer IPK: Ismaël Sanou (1, 6, 8, 10), Katharina Strohmeier (13); Institute (2) Fotolia: FERNANDO (5)

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