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 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)
Images
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Location

This is a set of Specific Objectives and Research & Innovation Objectives that is subject to a consultation in preparation of the Made In Europe Partnership.  For more guidance about the consultation, please see www.effra.eu/made-in-europe-state-play.

    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.

        Comment: 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 C&CS application is for HPDC and PIM sectors that are the most “defect-generating” and “energy-consumption” processes in EU industry
        Comment: The Intelligent Manufacturing approach will work at machine-mold project level to optimize/adapt the production of the specific product and can be extended at factory level to select/plan the appropriated production line
    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:

      All stages of production line are connecteted to the Data-Driven Digital Twin platform

      Comment:

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