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BOREALIS | The 3A energy class Flexible Machine for the new Additive and Subtractive Manufacturing on next generation of complex 3D metal parts.

01-01-2015

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31-12-2017

: 15 | : 1
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Results:
BOREALIS Machine : a new concept
BOREALIS Machine : a new concept

BOREALIS was born from the needs of those users that have started using additive manufacturing for small volumes production.

The main needs Borealis answers are : Big dimensions of the component to be produced, High deposition rate, Efficiency of the production

COMPOSITION | Ecosystem for Collaborative Manufacturing Processes _ Intra- and Interfactory Integration and Automation

01-09-2016

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31-08-2019

: 157 | : 7
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

See also D2.6 Lessons Learned and updated requirements report II

1. The COMPOSITION Marketplace Management System shall enable stakeholder to gain access to the COMPOSITION open marketplace.

2. COMPOSITION Marketplace(s) should have possibility of restricted access. 

3. The line visualization shall compare the actual processed units to the target ones. 

4. Alarms/Notifications are forwarded to subscribers depending on their impact level. 

5. It must be possible to reset an alert when the necessary measures have been taken. 

6. Ecosystem components should be deployed as Docker images. 

7. Agents shall be writable in any programming language. 

8. The Decision Support System shall import data coming from the simulation and prediction engines. 

9. Supplying companies register their products/services in specific topic(s) within the ecosystem. 

10. The needs and requirements of companies shall be registered/published within the ecosystem. 

Results:
Lessons Learned and updated requirements report II
Lessons Learned and updated requirements report II

COROMA | Cognitively enhanced robot for flexible manufacturing of metal and composite parts

01-10-2016

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30-09-2019

: 29 | : 4
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

Three industrial use cases have been addressed, corresponding to the Energy, Aerospace and Naval sectors.

On each use case, several robot manufacturing operation opportunities have been identified, with a large variety of applications that ensures industrial demonstrators on-site at the facilities of each one of the involved end-users.

The following operations have been addressed in the project:

  • Energy Sector: rack base weld grinding, nozzle non-destructive inspection, tube deburring
  • Aerospeace Sector: Jet engine part finishing, aircraft and T-profile machining 
  • Naval: Mould master model manufacturing

Each one of these insdustrial scenarios requires of different operational functionalities provided by each one of the CORO-modules. In the first two of them, the COROMA module must be able to localice and idetify the workpiece, generate the required trajectories for machining or inspection, execute the operations on it, avoiding collisions with objects and operators, and improving the overall performance by learning techinques. The Naval Sector applications sets the bar one step higher, as robot mobility along the workshops must be added in order to find a workpiece bigger than the robotic system itself.

FAR-EDGE | Factory Automation Edge Computing Operating System Reference Implementation

01-10-2016

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30-10-2019

: 70 | : 17
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

For being positively affected by the use of the FAR-EDGE Platform, use cases must have one or more of the following high-level requirements:

  • Distributed Automation: multiple (semi-)autonomous systems on the shopfloor having local resposibilities but global accountability.
  • Distributed Analytics: multiple local sources of raw data having high volume / velocity / variety characteristics (big data scenario).

Z-Fact0r | Zero-defect manufacturing strategies towards on-line production management for European factories

01-10-2016

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31-03-2020

: 35 | : 1
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

Neco use case requirements:

The following is a list about the most notable requirements NECO has identified and which the new platform developed at the Z-Fact0r project must fulfil:

  • One of the most important requirements is that, in order to pursue an on-line metrology ZDM strategy, the dimensional quality inspection should be performed in 3-4 minutes, which is the average for each machine cycle, due, of course, to the necessity of measuring each and every grinded tap.

 

  • Automatically measuring the relevant dimensional parameters for each tap comes a close second, because NECO wants to control the stability of the product. In this sense, metrological parameters such as flute length, point core diameter or flute angles should be measured by the new defect detection components.

The following parameters constitute the complete list of design parameters periodically measured after the grinding operation of taps:

  • Cutting angle: middle of entry
  • Cutting angle: first complete thread position
  • Cutting angle: flute at complete thread position
  • Point core diameter
  • Core diameter at flute
  • Land width at point
  • Land width at flute
  • Flute length

Further information about them will feature next at the 21, once the tap geometries which have been selected to constitute the Z-Fact0r use cases and defect types have been defined.

 

  • Checking the feasibility of, and, then, periodically recording some key parameters of the machine, such as vibrations in the wheel axis or grinding wheel speed, so as to have an effective control of the process, as well, and being able to predict machine behaviour and product quality.

PROGRAMS | PROGnostics based Reliability Analysis for Maintenance Scheduling

01-10-2017

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30-09-2020

: 19 | : 2
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

A survey among the customers of PROGRAMS industrial partners confirms that Predictive Maintenance practice will be effectively exploited ONLY IF it is:

  1. Affordable
  2. Confident and robust
  3. Easy to integrate
  4. Quick to deploy
 

In addition  Predicitive maintenance solutions must be flexible enough to allow different objectives, like the avoidance of sudden failure or the limitation of performace degradation.

UPTIME | UNIFIED PREDICTIVE MAINTENANCE SYSTEM

01-09-2017

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31-08-2020

: 39 | : 3
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment: The UPTIME Platform is deployed and validated against three industrial use cases:  (1) production and logistics systems in the aviation sector - FFT, (2) white goods production line - WHIRLPOOL  and (3) cold rolling for steel straps - MAILLIS.   The FFT use case deals with maintenance in highly complex transportation asset operations, some of which are mobile and subjected to diverse environments and a wide range of unpredictable environmental stress factors. Due to the critical nature of the deployment of these assets, the requirements are both technically and organisationally very high. The need has arisen to increase efficiency in maintenance execution as well as in reporting to the client, who in most of FFT projects is responsible for the logistics coordination of their assets.   The Whirlpool use case deals with the newly installed production line for clothes dryers, a complex automatic production line, which puts steel coils through a sequence of several steps of straightening, punching, seaming, flanging and screwing to eventually form the drum that holds and rotates the clothes in the dryer. The drum production equipment is very complex, highly automated and critical from many perspectives. It is critical to ensure the highest possible quality of the drum, which is the core component of the clothes dryer. At the same time, it is vital to keep the production equipment running efficiently and keep costs under control.   The Maillis use case deals with cold rolling mill for the production of steel strapping. MAILLIS‘s offer combines high-quality packaging materials and state?of?the?art technology, ensuring that metal producers enjoy reliable, durable, proven and high?speed strapping and wrapping technology at the optimal cost. MAILLIS uses cold rolling mills to produce rolling products with the smallest possible thickness tolerances and an excellent surface finish. The demand for changing over the milling rollers comes from either their regular wear or from an unexpected damage, which can occur due to either a defective raw material or an equipment malfunction. This usually happens every eight hours for the work rolls and every week for the backup rolls. After several regrinding, the diameter of the roll becomes so small that the rolls are no longer useful. It is expected to have a machine that reports its current health status along with the appropriate data analytics and metrics. UPTIME should also allow predictions about equipment‘s future health as well as recommendations for future actions and enable machines performing self-assessment, on which decision-making can be followed to advance equipment maintenance and facilitate the machine components and products life cycle.

ROSSINI | RObot enhanced SenSing, INtelligence and actuation to Improve job quality in manufacturing

01-10-2018

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31-03-2022

: 52 | : 4
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

The ROSSINI project foresees 3 use-cases related to Domestic Appliances Assembly (WHIRLPOOL), Electronic Components Production (SCHINDLER) and Food Products Packaging (IMA). The 1st use case aims at implementing real and efficient HRC which will allow to enhance human health and satisfaction in workplaces combining automation and the lean manufacturing concept thus reducing costs and avoiding dangerous operations for workers (requirement: improving safety in HRC and maintain the efficiency of the production line). The 2nd use case wants to redesign the actual production line  where individually separate but related items are grouped (the kitting step), packaged (the assembly step) and supplied together as one unit (requirement: strict collaboration between human operators and robot). The 3rd use case will leverage on a mobile robotic solution and an advanced smart sensing system to improve its current robotic solution for assisting operator in machine monitoring and maintenance (requirement: improve system performance in terms of speeds, handled objects and capabilities, whilst maintain operator safety)

COALA | COgnitive Assisted agile manufacturing for a LAbor force supported by trustworthy Artificial Intelligence

01-10-2020

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30-09-2023

: 37 | : 4
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Significant innovations, exploitable results and lessons learned, training aspects
Specific use case requirements
Comment:

COALA has three application cases that cover discrete manufacturing and process manufacturing: White goods, Textile and Detergent production. Each case provides one challenge where a potential solution has a significant economic value. The cases are real production environments and they will provide 1) key requirements for the COALA solution and 2) performance indicators for its evaluation.

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