MUlti-layers control&cognitive System to drive metal and plastic production line for Injected Components

Summary

High Pressure Die Casting (HPDC) of light alloys and Plastic Injection Molding (PIM) are two of the most representative large-scale production-line in manufacturing field, which are strategic for the EU-industry largely dominated by SMEs. Due to the high number of process variables involved and to the non-sinchronisation of the process control units, HPDC and PIM are most "defect-generating" and "energy-consumption" processes in EU industry. In both, sustainability issue imposes that machines/systems are able to efficiently and ecologically support the production with higher quality, faster delivery times, and shorter times between successive generations of products.

The MUSIC project is strongly aimed at leading EU-HPDC/PIM factories to cost-based competitive advantage through the necessary transition to a demand-driven industry with lower waste generation, efficiency, robustness and minimum energy consumption. The development and integration of a completely new ICT tool, based on innovative Control and Cognitive system linked to real time monitoring, that allow an active control of quality, avoiding the presence of defects or over-cost by directly acting on the process-machine variables optimization or equipment boundary conditions.

The Intelligent Manufacturing approach will work at machine-mold project level to optimise/adapt the production of the specific product and can be extended at factory level to select/plan the appropriated production line. The sensors calibration and quality control of measurements will be the pre-requisite of Intelligent Sensor Network to monitor the real-time production and specific focus will be also devoted to Standardization issues.

The challenge of MUSIC is to transform a production-rate-dominated manufacturing field into a quality/efficiency-driven and integration-oriented one to exploit the enormous (and still underestimated) potential of HPDC/PIM through collaborative research and technological development, along the value chain.

More information
Web resources: http://music.eucoord.com/
https://cordis.europa.eu/project/rcn//factsheet/en
Start date: 01-09-2012
End date: 31-08-2016
Total budget - Public funding: 9 302 073,00 Euro - 6 135 000,00 Euro
Call topic: Smart Factories: Energy-aware, agile manufacturing and customisation (FoF.ICT.2011.7.1)
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16-10-2021
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project_picturebig_1027-MUsic_intro.jpg
DDDT_platform_smartProdACTIVE.jpg
Location

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Significant innovations and achievements Significance of the results for SMEs
Specific use case requirements Lessons learned
    Comment:

    The data-driven digital twin in production line is a solution to measure, analyze and react oriented to zero defect manufacturing and to the maximization of the OEE improving the sustainability and profit of factory of future.

    The application of Smart Prod ACTIVE system has been demonstrated and validated at foundry level. In the frame of HPDC production process, Operator and Process manager take advantage by adopting a centralized remote control system supporting process monitoring and quality prediction in real time. The decision is supported by cause-effect correlations, and proper reactions suggested by a continuously updated meta-model. Re-usability and flexibility of the Smart Prod ACTIVE system also allow agile re-start in case of small batches production

    Comment:

    The challenge is the sensorization and data acquisition in the existing equipment not properly designed.

    The data miming, real-time alerting and cognitive predictive meta-modelling is not a chimera.

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Environmental sustainability Material efficiency Waste minimisation
Co-evolution of products-processes-production systems Reduction of energy consumption (in %) Reduction of waste (in %)

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Manufacturing the products of the future Resource efficient, sustainable products
Domain 2: Adaptive and smart manufacturing systems

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Advanced manufacturing processes Mechatronics Intelligent machinery components, actuators and end-effectors Information and communication technologies Digital manufacturing platforms
ICT solutions for modelling and simulation tools Modelling and simulation methods of manufacturing processes ... CAE models interoperability to allow fast and complete compl... MDO (Multidisciplinary Design Optimization)

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Field Device Work station Work centres - Production lines Enterprise - Factory
Connected Enterprises - Factories Connecting factories from different enterprises Manufacturing system levels
    Comment:

    A fundamental innovative characteristic of digital twin platform, called Smart Prod ACTIVE, is the predictive Quality model integrating multi-resolution and multi-variate process data in a collaborative way to support the decision making process by Operator (Quality oriented), Production manager (Efficiency oriented - OEE) and Business manager (Cost-oriented)

      Comment:

      The equipment and devices are sensorized to be deeper monitored

      Comment:

      Manufacturing cell is monitored with data acquisition from  any level.

      Comment:

      All different production lines and plants can be monitored wiht the same platform because it is felxible and scalable.

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Autonomous Smart Factories Pathway Data acquisition/monitoring/analysis (SCADA) implemented but... MOM-SCADA systems connected
Humans actively connected Autonomous /online/realtime Manufacturing Process Optimisati... Use of CAD systems

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OPC-UA Field Device Work station Work centres - Production lines Enterprise - Factory
Connected Enterprises - Factories AAA - Access, Authorisation and Authentication Open APIs and Communication Protocols Connectivity & network interoperability – communication prot... Real-time communication capability

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Proprietary software

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OPC-UA Standardisation via European Standardisation Organisations
Registered work item leading to EN (European Norm), TS (Tech...