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IFTInstitute for Production Engineeringand Laser TechnologyUniv.Prof. DI Dr. techn. habil. Friedrich BleicherSystem of systems for machining by standardized integrationUniv.Prof. Dipl.-Ing. Dr. techn. habil. Friedrich BleicherOct. 27, 2017

Austria – a country full of traditionAustria s hidden champions in industrial technologyIFT Institute for Production Engineeringand Laser TechnologySeite 2

TU WienAustria s largest Universtiy for TechnologyUniversity CouncilSenateRectoratef.l.t.r.: Kurt Matyas(Vice rector forStudies), Sabine Seidler (Rector),Johannes Fröhlich (Vice rector forResearch), Anna Steiger (Vice rector forHuman Resources and Gender), JosefEberhardsteiner (Vice rector forResources)PhysicsArchitecture and PlanningCivil EngineeringElectrical Engineering andInformation TechnologyTechnical ChemistryInformaticsMechanical and IndustrialEngineeringMathematics andGeoinformationIFT Institute for Production Engineeringand Laser TechnologySeite 3

IFT - Organization and Fields of ResearchInstitute for Production Engineeringand Laser TechnologyHead: Univ.Prof.Dr. F. BleicherTechnologyArea of ResearchManufacturing TechnologyArea of ResearchLaser TechnologyUniv.Prof.Dr. F. BleicherUniv.Prof.Dr. A. OttoMachine Tools andProduction SystemsMetrology andQualityManufacturingAutomationCutting TechnologyCompetence Centerfor Digital ProductionNon ConventionalMachiningControl andAutomationTechnologyRSF ZerspanungstechnikHaas WerkzeugmaschinenMesstechnik MöllerIFT Institute for Production Engineeringand Laser TechnologyB&RSeite 4

Outline1Introduction2Manufacturing system of the future3System integration4Pilot factory5SummaryIFT Institute for Production Engineeringand Laser TechnologySeite 5

Outline1Introduction2Manufacturing system of the future3System integration4Pilot factory5SummaryIFT Institute for Production Engineeringand Laser TechnologySeite 6

Why industry 4.0?Index of seasonally adjusted unit labor costs%Euro Area (18), index: 1999more competitiveless competitiveSource: OECDResult: 285 bn Export surplus 2014yearIFT Institute for Production Engineeringand Laser TechnologySeite 7

Kontratieff - cycles – technology innovationsKontratieff - cyclessteam engine,textile industryelectronics,control onprosperitymining,clothingrailway,steel e,autonomous systemsI4.0LeanCIMpublic transport1850information,informationtechnology,bio technologymass production1900IFT Institute for Production Engineeringand Laser TechnologyIndividual ication1990Seite 8

Trends in production engineeringHostory and future of manufacturing – Industry 4.0MechanisationChronologyHigh volume prod.AutomationIntelligence18. century19. century20. century21. centuryManufactoryTaylorismToyota SystemLearning FactoryProduction structureFactory systemFocussingModularisationVirtualisationProduct structureIndividual partsStandardisationComplexityAdaptive variabilityAll-rounderSpecialistFlexibleSelf organizingRegional ensive useIntensive useCareful use of res.RecyclingProduction systemFlexibility vs.ProductivityWorkerMarketsResource efficiencyIFT Institute for Production Engineeringand Laser TechnologySeite 9

Outline1Introduction2Manufacturing system of the future3System integration4Pilot factory5SummaryIFT Institute for Production Engineeringand Laser TechnologySeite 10

Micro - SensorsJohnsGizmag.comHopkins Univ.Univ. of Tokyoceatec.comOrgan-on-a-Chip formedical testsFlexible pressuresensors for „robot- skin“MEMS multi-axle accellerationsensorsUsage within machinetools?16 SensorsIFT Institute for Production Engineeringand Laser TechnologySeite 11

Global information networksNew communication standardsmake the world connectedIPv4 with 232 ( 4,3 Billion 4,3·109)IPv6 with 2128 ( 340 sextillion 3,4·1038)i.e. magnification of Factor296 ( 7,9·1028)Each component, each part or product,etc. can be identified and addressed byan individual internet-connectivity in thefuture.IFT Institute for Production Engineeringand Laser TechnologyEarth: Total surface: 510.000.000 km² Water:360.570.000 km², 70,7 % Land: 149.430.000 km², 29,3 % IPv4:Land28,78 Addresses/km²8,43 Addresses/km² IPv6:2,28 1018Addresses/mm²6,67 1017 Addresses/mm²Seite 12

New machine tool conceptsKrause&MauserComparison of different machine tool conceptslarge batch productionhigh productivityunflexiblehigh productivityflexible and reconfigurable machinestransfer linenext generationmanufacturing systemsflexible transfer lineProductivityAnforderungen anWerkzeugmaschinenflexiblemanufacturingsystemhigh flexibilitylow productivityflexiblemachining cellmachining IFT Institute for Production Engineeringand Laser TechnologySeite 13

Flexible machining cells - plug & produceSensor integration in the tool – process and tool condition monitoringinformation for process virtualization and planningMES, i.e. SAP MIIOPC-UA ClientOPC-UA Clientmobile APPDevelopment platform forplug-and-produce-conceptOPC-UA ServerCell sequence controlOPC-UA ClientsOPC-UA ServerOPC-UA ServerOPC-UA ServerABB PC SDKIFT Institute for Production Engineeringand Laser TechnologyMODULE uagripper(SYSMODULE)RECORD gripperstring classification;string name;string model;tooldata td;string active pricipal;num grip force;num idle stroke;num payload;num clamping time;num opening time;num aRobotDataSeite 14

Cyber Physical Production Systems (CPPS)„From Batch to Lot-Size 1“Cyber SpaceAvailabilityQualityErrorQuantityEnergy DemandScheduleRessourceEnergy SupplyReal SpaceSupply e (Product und Production System)DevelopmentVirtualityProduction„digital twin“IFT Institute for Production Engineeringand Laser TechnologyUsage/OperationDisposal„real twin“RealitySeite 15

Outline1Introduction2Manufacturing system of the future3System integration4Pilot factory5SummaryIFT Institute for Production Engineeringand Laser TechnologySeite 16

System integration Develop the manufacturing systems of the future Overcome existing process limitations Increase Performance Optimization of Processessmart, connectedmachine toolsystem of systemsproduction systemsmart machine toolmachine toolAdaptive Production SystemIFT Institute for Production Engineeringand Laser TechnologySeite 17

Roadmap to Adaptive Production SystemsSensing & Monitoring Sensor Integration in: Tool Fixture Spindle and machineActuator integration Actuator Integration in: Tool Fixture SpindleHybrid machinesSmart mechatronic systems HSC milling Jig grinding Laser machining Tombstone 4.0 Flexible gripper .Algorithms Development of Algorithms Defining new KPIs Data visualizationPlug & Produce Flexible connection and orchestration ofmanufacturing equipmentConnectivitySelf Description Semantic description offunctions and structure Standardized communication technology(OSI 5-7) Offer services, static description anddynamic behaviorIFT Institute for Production Engineeringand Laser TechnologySeite 18

Improved production processesovercome existing process limitations high performance cutting technologies MHP - machine hammer peening process integration VAM - vibration assisted machiningmulti-dim.VA machine tableVA turning of X2CrNiMoN22-5-3 (178 Hz, 10 µm)IFT Institute for Production Engineeringand Laser Technologymulti-dim.VA spindleSeite 19

Sensing and adapting machine toolscontrol, sensor and actuator integration communication technologies interpretation (in-process control) development of algorithms connectivity (OPC UA interfaces)sensory tool holderintelligent tombstoneIFT Institute for Production Engineeringand Laser TechnologySeite 20

Increase of productivityin-process-measurement and real time closed loop control offershigher productivityEarly detection ofdynamic instabilitiesTime criticalInitiation ofcountermeasuresPrevention ofinstable processesIFT Institute for Production Engineeringand Laser TechnologySeite 21

Sensor integration and communicationRaspberry Pi Relais-Platine(Webserver)sensory fixture – example: tombstone show case made of transparent acrylic glassbattery powered Raspberry Pi as controlhardwarepneumatic cylinders as actuators,temperature sensors, and currently alsostrain gauges implementedwebserver and OPC UA Server ry forcontrolFeedthrough for Pneumatic (1 x)and electric (1 x 24 V)IFT Institute for Production Engineeringand Laser TechnologySeite 22

Integration and communicationmanufacturing systems of the future collect, store, visualize & analyze data orchestration and integration of hardware (sensory tool holder, etc.)OPC-UAadministration shellIFT Institute for Production Engineeringand Laser Technologyinterfacereal time communication byOPC-UA TSNSeite 23

Production information systemCompetitiveness by production information roductionIFT Institute for Production Engineeringand Laser TechnologyQualityassuranceFinalinspectionSeite 24

Outline1Introduction2Manufacturing system of the future3System integration4Pilot factory5SummaryIFT Institute for Production Engineeringand Laser TechnologySeite 25

Pilot factory 4.0 topics and scenariosICT Infrastructure, universal vertical integration/ Partner ATOSPLM (Siemens Teamcenter)Project & Schedule Mgmt. VisualizationCAX Integration (MCAD)Document Mgmt.ERP IntegrationRelease Mgmt.Manufacturing ProcessProduct Data Mgmt.MES(SAP MII/ME)ERP (SAP)Master DataLong Term PlanningSales and OperationsProduction Order CreationDemand ManagementCapacity RequirementsMaterial RequirementsProduction executionERP IntegrationKPI Mgmt.SchedulingTool Mgmt.Electronic Work InstructionsIn-Process MonitoringWIP Reporting, TraceabilityResource Status, DashboardNon Conformance Mgmt.MaintenanceProduction / EMCO, IGMLogistics / Neobotix etc.Assembly/ ABB, etc.Reconfigurable, adaptivemanufacturing, high mix and lowvolume production, integration MES,M2M Communication,Integration ofadditive and subtractiveproduction,integration logistics,RFIDAdaptive logistic system (Storage,autonomous transport) as trailblazerof industry 4.0 using conveyancemodules acting autonomous withinthe production system.Integrated cyber- physical assemblyrobotics including human assistance,intelligent assistance systems, andhuman- robot interactionIFT Institute for Production Engineeringand Laser TechnologySeite 26

3D - Printer as demo - productIFT Institute for Production Engineeringand Laser TechnologySeite 27

Pilot factory 4.0 in Aspern/ ViennaIFT Institute for Production Engineeringand Laser TechnologySeite 28

Pilot factory of TU WienNetwork/ServerCommonroomA1SmallEntrance omMetall3DDruck3D Printing tpresentationRampM4Control panelMachiningFTSMillingWarehouseTurningOfficeIFT Institute for Production Engineeringand Laser TechnologyWelding/additiveSeite 29

Pilot factory of TU WienWarehouse and assembly line with agvIFT Institute for Production Engineeringand Laser TechnologySeite 30

Pilot factory of TU WienMachning cell with robots and agvmilling – turning – welding/additiveIFT Institute for Production Engineeringand Laser TechnologySeite 31

Outline1Introduction2Manufacturing system of the future3System integration4Pilot factory5SummaryIFT Institute for Production Engineeringand Laser TechnologySeite 32

Industry 4.0„The greatest danger in times ofturbulance is not the turbulence itself,but to act with yesterday‘s logic“„I hear and I forget.I see and I remember.I do and I understand.“Peter Drucker, US-EconomistConfuciusPilot factoryBleicher, Hunschofsky: IoT-Conference,San Diego, 2016IFT Institute for Production Engineeringand Laser TechnologySeite 33

MES, i.e. SAP MII Cell sequence control OPC-UA Server OPC-UA Client OPC-UA Client OPC-UA Server OPC-UA Clients Flexible machining cells - plug & produce Development platform for plug-and-produce-concept mobile APP Controller ABB PC SDK Procedures GripperData RobotData MODULEuagripper(SYSMODULE) RECORDgripper stringclassification; stringname;