NETWORKED, ADAPTIVE PRODUCTION

Transcription

1 High Performance Center Networked, Adaptive Production

2 NETWORKED, ADAPTIVE PRODUCTION Nowadays, production companies are practically living in two different worlds: in a real one where components, tools and machines exist, and separated from that in a digital world where process and components data is stored. To allocate a component to this data, an employee must know exactly where to find necessary data. The transition to Industrie 4.0 is set to close the gap between real data and the digital world. Manufacturing a product or component in compliance with specified tolerances that is the primary aim in production. Therefore, it is important to record all data that can give information on the intermediate state along the process chain. Such valuable information can be obtained by machineintegrated sensors, which signal to the user whether there is potential violation of tolerances. The High Performance Center Networked, Adaptive Production deals with developments for Industrie 4.0 that are going to be implemented in the form of six practical pilot lines. These pilot lines are divided into three fields: energy, mobility and health. works is to make the manufacturing of technical as well as biopharmaceutical products significantly more flexible and efficient. High-performance partners from the fields of IT system providers, machine manufacturers and production companies have already confirmed their cooperation. The High Performance Center is an initiative between the federal state of North Rhine-Westphalia and the Fraunhofer- Gesellschaft, which receives extensive support from industry. It was founded in late 2016 in Aachen with a total budget of 6.4 million euros. The High-Performance Center generates an open research platform and test environment for the industry, where new concepts for digital production can be probed. Industrie 4.0 for demanding value-added chains At the High Performance Center, the three Aachen-based Fraunhofer Institutes for Production Technology IPT, for Laser Technology ILT as well as for Molecular Biology and Applied Ecology IME will collaborate with RWTH Aachen University and renowned industrial partners to develop production systems and value-added chains in the sense of Industrie 4.0. A validation of the developments will be carried out by means of the pilot lines. The overall aim of the conducted

3 ENERGY MOBILITY Manufacturing and repair of gas turbine blades Series production of turbine components For manufacturing and repair of gas turbine blades, the partners of the High Performance Center examine additive and subtractive manufacturing and repair processes such as laser cladding, cutting as well as sensor integration and process chain configuration. By recording sensor data during the process, details enabling a specific process adaptation become visible. Optimized planning tools are supposed to ensure data consistency and planning transparency. Here, the High Performance Center closely works together with the partners from the machine tool and turbomachinery industry for aviation and energy generation. Design and production of battery modules In an additional field of application, the partners of the High Performance Center examine the adaptive production of battery modules, taking into account given restrictions such as installation space and weight as well as electrical properties. By using different cell types, suitable modules shall be manufactured in small to medium-sized quantities. Both laser welding and laser bonding are employed as manufacturing technologies for the connecting elements. Objectives Early information on advantages and disadvantages of different manufacturing concepts Increased component quality at shorter processing times Automated error identification and correction Documentation of all process steps in the digital twin Series production of turbine components requires economic process chains. Additionally, process documentation is required for mandatory certification. Within this project, data is collected by means of standardized OPC UA interfaces and is made available for simulation and documentation along the entire process chain. Tool making for automobile applications Tool making is dominated by single-part production, which requires the successful implementation of the first part right principle. Different process chains, which are pre-modeled and then stored in a database, form the basis for the automation of tool making: information from models and databases contributes to making decisions regarding production progress at the latest possible time, ideally in real-time. Objectives Simulation based on real data for shorter process development cycles and successful repair Planning tool for concrete processing sequence based on the desired product performance Digital recording in real-time, even in series production Predictive maintenance for increased machine availability

4 HEATLH A classic, biopharmaceutical production process to create monoclonal antibodies is transferred into a networked, adaptive production. Today, such antibodies are applied in cancer therapy, for instance. Upstream production: seeding, cultivating and harvesting Objectives GMP-compliant, cost-efficient manufacturing of antibodies, vaccines, enzymes and recombinant proteins with consistent quality and high yield Improved workload of the production lines at a reduced batch size As a first step, the High Performance Center inspects upstream production, i.e. the process chain seeding cultivating harvesting, aiming for a continuous optimization of plant growth and expression level in order to maximize the productivity of recombinant proteins. Downstream processing: from extraction and filtration to the biopharmaceutical product This phase, utilizes the process results from the upstream production. By means of new process models, the biopharmaceutical product quality and yield can be monitored more reliably and, hence, be improved. For this purpose, real-data acquisition and processing is the central aspect. They are the basis for an extensive, holistic process simulation and can contribute to speed up product approval. The simulation models determine the reference variables of the process and make sure it runs under ideal conditions at all times. Due to its high flexibility and adaptability, the system is of particular interest to industrial partners from the pharmacy, cosmetics and agriculture sectors. High Performance Centers for sustainable site development As co-operations between both university and nonuniversity research as well as industrial companies, the High Performance Centers are supposed to generate a unique position on a national and European level and, at the same time, strengthen international competitiveness. They organize the close alliance with economy and, thus, expand the national and international appeal of leading regions and networks and their key topics, with a view to the competitiveness of the German industry. The Fraunhofer concept of the High Performance Centers is an offer to the Federal Government and the federal states for the innovation- and application-oriented assurance of excellence of the German industry in the given key topics. The concept is to be understood as the Fraunhofer- Gesellschaft s preparation for the Excellence Initiative.

5 PRODUCING IN THE SMART MANUFACTURING NETWORK Industrie 4.0 in the High Performance Center: Digitization and Networking of Production The central structure of the High Performance Center is manifested in the Smart Manufacturing Network, an IT network that provides relevant machines, production systems, databases and simulation systems. The employee is connected to the process through mobile devices such as tablets or data glasses, which enable him to directly interact with and control all subsystems and access production data. With the help of such decentral and modular systems, manufacturing processes and process chains can be planned, carried out, monitored and reconfigured more quickly and more cost-efficiently. The connectivity of production systems is supposed to generate adaptable systems that allow for an individualized production of various components in small quantities and at a virtually identical cost structure from design to recycling. The comprehensive technological understanding of the three Fraunhofer Insitutes, regarding the individual processes and process chains in the pilot lines, is the prerequisite for generating a nearly complete, virtual representation of the respective processing states along the manufacturing chain. This digital twin is stored within the Smart Manufacturing Network for every component and is thus available for all systems. The objective of the institutes is to transfer this detailed and technological process knowledge into concrete technological applications by means of suitable data architectures, big data tools and cloud services in the sense of Industrie 4.0. Digital Twin Cloud (Virtual Fort Knox) CAx framework function blocks Technology database Availability of process and production data Data analytics Smart Manufacturing Network (SOA) Geometry Material Real data Historical data Functional data ERP PLM Component Functional assignment by CAx framework LMD SLM Metrology Employees Milling Raw Part Simulation EDM Laser structuring SOA Service Oriented Architecture OPC UA* Interface M2M-Communication Protocol * Open Platform Communication Unified Architecture

6 Fraunhofer in Aachen Your partners in the High Performance Center Networked, Adaptive Production Fraunhofer Institute for Production Technology IPT Dr. rer. nat. Thomas Bobek Steinbachstrasse Aachen Germany Phone Fraunhofer Institute for Laser Technology ILT Dr.-Ing. Alexander Olowinsky Steinbachstrasse Aachen Germany Phone Fraunhofer Institute for Molecular Biology and Applied Ecology IME Dr. Johannes Buyel Forckenbeckstrasse Aachen Germany Phone johannes.buyel@ime.fraunhofer.de With the kind support of the Land North Rhine-Westphalia