FRAUNHOFER IFF MAGDEBURG AT THE FOREFRONT OF DIGITAL MANUFACTURING. Christian Blobner, Lecco, February 15, 2018

Transcription

1 FRAUNHOFER IFF MAGDEBURG AT THE FOREFRONT OF DIGITAL MANUFACTURING Christian Blobner, Lecco, February 15, 2018

2 Finance volume Contract Research The Fraunhofer-Gesellschaft at a Glance The Fraunhofer-Gesellschaft undertakes applied research of direct utility to private and public enterprise and of wide benefit to society. 24,500 staff 2.1 billion 1.9 billion Major infrastructure capital expenditure and defense research Almost 30% is contributed by the German federal and Länder Governments More than 70% is derived from contracts with industry and from publicly financed research projects. 69 institutes and research units

3 Fraunhofer IFF in figures 188 employees Research budget 19.6 million Operates two research buildings incl. various laboratories Project office in Bangkok, Thailand Active on six continents Employees Research Budget Institute Director: Prof. Michael Schenk Revenue coming from Industry Public research grants Basic funding 3

4 Digital Engineering and Operation Fraunhofer IFF as Technology Partner Interrelated Specializations for Fields of Research Specializations Robotics Fields of Research Smart Work Systems Measurement and testing Process engineering Logistics zones Assistance and training systems Resource Efficient Production and Logistics Convergent Supply Infrastructures little, medium, great relevance of a specialization for a field of research 4

5 Digital Engineering and Operation Design Review Engineering Manufacturing Assembly Maintenance Functional Test Mechanics Electronics Control systems Maintenance Assistant systems Visual interactive repair instructions Education and Training Technical staff Operation service Assembly service Virtual Knowledge Base Factory Planning Layout planning Process planning Technical Documentation Visual interactive catalogs Electronic manuals Job Preparation Work scheduling Resource optimization Logistics functions 5

6 Integrated and Parallel Product and Manufacturing System Design for LANXESS AG Use of virtual models to plan, develop and prototype the manufacturing system for innovative water filters in parallel to the product development process Planning and development of several (semi) automated manufacturing systems Goal: Fully automated production facility (2020) 1st generation ManualWinder (2011) Linkage concept study (2014) 2nd generation AutoWinder I (2012) SideCut II (2013) 3rd generation AutoWinder II (2017) Manual operation Manual operation Other process steps 6

7 Integrated and Parallel Product and Manufacturing System Design for LANXESS AG Complexity AutoWinder 1 consisting of a total of thirteen modules 10,000 components 800 sensors 150 pneumatic actuators 30 electric drives Digital Engineering and Operation Constant analysis: Analysis of nominal and actual data from the virtual and the real system Benefits Fraunhofer IFF Functioning Digital Twin: Error codes including solution strategies Maintenance data Supporting operational assistance system 7

8 Feedback quality measures into production processes Using virtual data as augmented reality overlay for a visual assistance and inspection systems for assembly jobs Improve hand-off between manual preassembly and machine processing Increase process reliability and zerodefect manufacturing Augmented reality: Information supplied by camera images of the assembly scene, overlaid with 3D CAD models Virtual templates to position and align components Upgradable with an inspection assistant Fraunhofer IFF Fraunhofer IFF 8

9 Feedback quality measures into production processes Initial situation Production line for alloy wheels Inline quality control at process end Geometric measures / deviations with optical 3D sensors Goal Find leading cause of quality deviations in digital data Ascribe cause of deviations to production machines by connecting digital production data and sensor data 9

10 Feedback quality measures into production processes Method 1. Connect data sources in production line 2. Synchronous data from machine components and SPS controller (e.g. operating time, rotation rates, energy consumption) 3. Capture quality data with optical 3D measuring system (e.g. drilling diameters, distances, run outs) 4. Run (Big) Data analytics Result Correlation of quality deviations and behavior of system and process components Quality trends, Prediction of maintenance intervals and failure probabilities 10

11 Safe Human Robot Collaboration Tactile sensors for safety and haptic interaction Applied all around the platform, linear axis and as bumper With integrated damping material As input device for simple and intuitive movement of platform and linear axis Tactile sensors 11 This project has received funding from the European Union s FP7 research and innovation programme under grant agreement No

12 Fraunhofer Telematics Production and logistics processes Exchange of production and logistics data Providing necessary data for implementation of subsequent process steps Documentation of process steps Current problems Multitude of actors involved Information exchange often via phone, s, paper documents, etc. Media breaks Use of unstructured data Significant efforts for searching relevant information or efforts of documentation (also time lags in keeping information current) 12

13 Fraunhofer Telematics 13

14 Digital Engineering at the Fraunhofer IFF Virtual Technologies as Enablers of Industry 4.0 Digitalization of Systems Digitalization of Processes Digitalization of Infrastructure Source: acatech 2013, Industrie_4.0_accessible.pdf 14

15 Fraunhofer-Institut für Fabrikbetrieb und automatisierung IFF Sandtorstr Magdeburg Christian Blobner International Business Development Tel.: Fax: