Twin-model based virtual manufacturing for machine tool-process simulation and control

Summary

Europe is the world’s largest manufacturer of machine tools but this position is threatened due to the emergence of Asian countries. However, Europe has world-class capabilities in the manufacture of high-value parts for such competitive sectors like aerospace & automotive and this has led to the creation of a high-technology, high-skill industry. European machine tool builders, part manufacturers and other agents have to work together to increase the competitiveness of European manufacturing industry.

Simulation tools are currently a key complement to European machine tool industry expertise but new integrated approaches are needed. The main objective of Twin-Control is the development of a simulation and control system that integrates the different aspects that affect machine tool and machining performance.

This holistic approach will allow a better estimation of machining performance than single featured simulation packages, including lifecycle concepts like energy consumption and end-life of components. This integrated concept will also enhance the necessary collaboration between machine tool builders and part manufacturers.

The specific industrial objectives are:

  • Getting machines that work as designed faster (10% reduction)
  • Getting production processes that work as planned faster (20% reduction)
  • To get a first-time-right part manufacturing (75%) • To increase production time trough model-based control (increase of 1-2%)
  • To reduce energy consumption (25-50%)
  • Improve machine reliability and increase machine up-time due to a proactive maintenance (2-4.5%)

All these will contribute to reduce machine tool life cycle costs (15 %) with a reduction of O&M costs in the range of 25%.

The project considers the validation and demonstrator in real production scenarios in aerospace and automotive industries. Added to this, 3 demonstrators will be set-up in three pilot lines for spreading results beyond the project end

More information
Web resources: http://twincontrol.eu/
https://cordis.europa.eu/project/rcn/198381/factsheet/en
Start date: 10-01-2015
End date: 30-09-2018
Total budget - Public funding: 5 600 241,00 Euro - 5 600 241,00 Euro
Call topic: Integrated design and management of production machinery and processes (FoF.NMPB.2015.14)
Cordis data

Original description

Europe is the world’s largest manufacturer of machine tools but this position is threatened due to the emergence of Asian countries. However, Europe has world-class capabilities in the manufacture of high-value parts for such competitive sectors like aerospace & automotive and this has led to the creation of a high-technology, high-skill industry. European machine tool builders, part manufacturers and other agents have to work together to increase the competitiveness of European manufacturing industry.
Simulation tools are currently a key complement to European machine tool industry expertise but new integrated approaches are needed. The main objective of Twin-Control is the development of a simulation and control system that integrates the different aspects that affect machine tool and machining performance. This holistic approach will allow a better estimation of machining performance than single featured simulation packages, including lifecycle concepts like energy consumption and end-life of components. This integrated concept will also enhance the necessary collaboration between machine tool builders and part manufacturers.
The specific industrial objectives are:
• Getting machines that work as designed faster (10% reduction)
• Getting production processes that work as planned faster (20% reduction)
• To get a first-time-right part manufacturing (75%)
• To increase production time trough model-based control (increase of 1-2%)
• To reduce energy consumption (25-50%)
• Improve machine reliability and increase machine up-time due to a proactive maintenance (2-4.5%)
All these will contribute to reduce machine tool life cycle costs (15 %) with a reduction of O&M costs in the range of 25%.
The project considers the validation and demonstrator in real production scenarios in aerospace and automotive industries. Added to this, 3 demonstrators will be set-up in three pilot lines for spreading results beyond the project end

Status

SIGNED

Call topic

FoF-14-2015

Update Date

07-11-2021
Images
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Location

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Engineering tools Cloud computing, edge computing Data acquisition Data processing Data analytics
Data storage Data modelling Data collection, storage, analytics, processing and AI Cognitive and artificial intelligence (AI) technologies - ma... Human Machine Interfaces

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Design/development Product design/development Product use phase Field Device Use-phase of manufacturing system (producing products)
Product component Product Production of product Enterprise - Factory Connected Enterprises - Factories

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Open APIs and Communication Protocols APIs and Integration Protocols Field Device Data communication infrastructure Real-time communication capability Product
Interoperability (ICT) Platform level interoperability AAA - Access, Authorisation and Authentication Safety Enterprise - Factory Connected Enterprises - Factories