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

01-09-2012

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31-08-2016

: 13 | : 6
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Significant innovations, exploitable results and lessons learned, training aspects
Significant innovations and achievements
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

PSYMBIOSYS | Product-Service sYMBIOtic SYStems

01-02-2015

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01-02-2018

: 80 | : 3
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Significant innovations, exploitable results and lessons learned, training aspects
Significant innovations and achievements
Comment: The project applies a symbiotic innovation process to the use cases in order to support the search for competitive product-service systems. The aim is to nurture and develop new products and associated services and also the related product-service system business models for the innovation chain in order to realize competitive PSS.

HORSE | Smart integrated Robotics system for SMEs controlled by Internet of Things based on dynamic manufacturing processes

11-01-2015

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30-04-2020

: 57 | : 4
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Significant innovations, exploitable results and lessons learned, training aspects
Significant innovations and achievements
Comment:

HORSE initiated the transformation of technology labs into Competence Centres closer to industry and the regional ecosystem. HORSE also launched the concept of 'Competence Centre Networking', where not only expertise was shared, but the experience of existing Technology Labs/Competence Centres was used for the establishment of new ones. As such, HORSE is the predecessor of the DIH concept, and was actually involved in the mentoring program of new DIHs, assisting in the establishment of even more such Innovation Hubs. Regarding the technologies developed, HORSE designed a reference Industry 4.0 architecture, which is applicable in manufacturing environments and taking into account all the different resources (humans, robots, machinery, sensors, etc.) that are present in a production shop floor. 

A4BLUE | Adaptive Automation in Assembly For BLUE collar workers satisfaction in Evolvable context

01-10-2016

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30-09-2019

: 15 | : 4
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Significant innovations, exploitable results and lessons learned, training aspects
Significant innovations and achievements
Results:
Landing gear retraction actuator assembly: Manual deburring operation | Assembly process (CESA)
Landing gear retraction actuator assembly: Manual deburring operation | Assembly process (CESA)

A collaborative robotic cell has been implemented for the deburring operation where the robot executes the most exhausting phases, while the worker focuses on final quality inspection. Regarding the assembly process, an AR solution, using ultra-real animations has been implemented to guide operators through tasks. Additional AR functionalities include the visualization of textual information (tips, best practices…), access to technical documents and voice recording

Collaborative assembly in a fenceless environment (IK4-TEKNIKER)
Collaborative assembly in a fenceless environment (IK4-TEKNIKER)

The assembly collaborative robot considers both the operation being performed and operator’s anthropometric characteristics for control program selection and part positioning. Besides, the workplace includes multimodal interactions with both the dual arm assembly and logistic robots as well as with the Manufacturing Execution System. Verbal interaction includes natural speaking (i.e. Spanish language) and voice-based feedback messages, while nonverbal interaction is based on gesture commands considering both left and right-handed workers and multichannel notifications (e.g. push notifications, emails, etc.). Furthermore, the maintenance technician is assisted by on event Intervention request alerts, maintenance decision support dashboard and AR/VR based step by step on the job guidance.

Complex, manual hydraulic system assembly (AIRBUS)
Complex, manual hydraulic system assembly (AIRBUS)

The proposed solution comprises an adaptive smart tool and an AR instruction application using HoloLens wearable devices and a framework for ensuring digital continuity starting from the data recorded in the system for manufacturing engineering up to the execution and analysis phase

Final assembly of electric vehicles (RWTH Aachen University)
Final assembly of electric vehicles (RWTH Aachen University)

An AR based solution is proposed for instructions visualization enabling also on-job training activities and guidance. Regarding the ergonomics, an autonomous tool-trolley has been integrated including voice command and AR based gesture steering.

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
Significant innovations and achievements
Comment:

The COROMA modular platform is an innovative approach that has developed seven fuctional modules to improve the performance of already existing robotic systems:

  • CORO-OPTIP: this module equips the robot with process awareness to detect, for example, vibrations during drilling that will trigger a reaction, or check tool wear if a sanding operation is being carried out.
  • CORO-MOB provides the robot with mobility, so it can move autonomously through the workshop.
  • CORO-SAFE offers artificial vision so that the robots can detect the presence of humans and make way.
  • CORO-COOP focuses on providing developments for a communication platform so that the robot can interact with other machines and robots.
  • CORO-SENSE is a vision module implemented by means of camera systems and laser technology, so that it can understand the environment and find the part on which they must work.
  • CORO-PROG minimum programming module allows the robot to respond to operator’s instructions, and to respond to visual instructions in a simple way.
  • CORO-HAND allows the robot to pick up tools and provide the system with dexterity.

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
Significant innovations and achievements
Comment:

FAR-EDGE demostrates the feasibility and business value of Edge Computing (EC) applied to manufacturing, using Distributing Ledger Technology (DLT) as the key enabler. DLT allows several autonomous local processes to cooperate as peers in the scope of the same global process, the required state synchronization and common business loging being implemented by Smart Contracts. This approach, if applied correctly, results in totally decentralized and fail-safe CPS that are still easily monitored, controlled and managed centrally.

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
Significant innovations and achievements
Comment:

Twenty-six results were identified in total and their beneficiaries hold exclusively the ownership rights, with the exemption of a single shared result. All these results add up to the integrated Z-Fact0r solution which demonstrates certain innovative and unique features. As a matter of fact, Z-Fact0r is a holistic & innovative ZDM solution which increases overall quality & customer satisfaction by reducing production costs, energy & material consumption, while utilizing almost all the state-of-the art techniques for implementing ZDM. Zero-Defect Manufacturing is currently the new trend in multi-line manufacturing, and therefore companies offering solutions similar to the Z-Fact0r emerge. However, at the moment, there are very few (if any) platforms -such as the Z-Fact0r- available in the market, offering such integrated quality control for the industry.

ZAero | Zero-defect manufacturing of composite parts in the aerospace industry

01-10-2016

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30-09-2019

: 20 | : 3
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Significant innovations, exploitable results and lessons learned, training aspects
Significant innovations and achievements
Comment:

The project developed a zero-defects manufacturing process for large composite parts. Various monitoring systems analyse key steps in the process (lay up, infusion, curing) to provide immediate feedback to the process. Efficiency increases of 30% have been realized.

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