Industry 4.0 Tools

– Integrated Modelling and Sensing for Manufacturing

9 May 2019

DTU Lyngby
Meeting room S02
Anker Engelundsvej 1
2800 Kgs. Lyngby

The ongoing digital transformation of industry is changing the future of manufacturing. For industrial production one important aspect is the integration of model based off-line prediction and optimization with real time information from sensors integrated in machines and production lines. Reduced order models with lower computational requirement and fast response time can therefore run on quasi real time generated data providing the means for real time optimization and correction, fault prevention and predictive maintenance. Integration, interconnection and communication are indeed key for harvesting the possibility provided by the latest technological developments.

The seminar consists of a blend of talks from industry and academia. It offers an overview of the state of the art in modelling and sensing for I4.0 implementation and presents integrated solutions by major players within the manufacturing and automation industry.

09:00 - 09:30 Registration
09:30 - 09:40 Welcome
09:40 - 10:15
Current Roles of Monitoring & Simulation in Additive Manufacturing

Sankhya Mohanty, Researcher, PhD, DTU Mechanical Engineering

Industrial adoption of additive manufacturing requisites the ability to certify the manufacturing process – a key aspect being the effective process control. The Industry 4.0 wave has initiated a shift towards in-line monitoring of the process with a goal of predicting & in-situ correcting the manufacturing defects. Prediction of such defects would draw upon phenomenological models and/or multi-physics simulations that can provide a link between nominal process settings, measured parameters and emergent defects (e.g. dross, warpage, porosity, etc.). The talk will highlight the activities within pan-European and Danish national projects such as Precision Additive Metal Manufacturing (PAM^2), AMLine 4.0 and MADE Digital in the fields of AM process metrology and simulations.

Sankhya Mohanty is a Researcher at the Department of Mechanical Engineering at DTU in the field of simulation of additive manufacturing processes. He has over 7 years of experience in additive manufacturing and laser-based processing with a focus on process optimization.
10:15 - 10:50
Modelling of Surface Generation in Precision Machining for Offline Tool Path Optimization

Giuliano Bissacco, Associate Professor, DTU Mechanical Engineering

Surface generation in Precision Machining is affected by a complex interaction between cutting edge and workpiece material leading to machining errors such as dimensional and geometrical deviations, surface artefacts and surface topography errors. By fast modelling approaches of the tool-workpiece interaction, it is possible to provide point by point evaluation of geometrical errors and surface quality along the tool trajectory. This presentation shows the benefits and capabilities of the modelling solutions of machining processes developed at DTU and how these can be implemented to enable fast off line optimization of the process and thus prevent defects generation.

Giuliano Bissacco is Associate Professor in tooling processes and process chains at DTU Mechanical Engineering. He holds a PhD in Manufacturing Engineering (2004) and an MSc in Mechanical Engineering (2000). His activity encompasses development, analysis, modelling and optimization of precision and micro manufacturing processes and systems.
10:50 - 11:10 Break
11:10 - 11:45
Requirement for the Simulation Tool for Use during the Product Lifecycle

Thure Ralfs, Managing Director, Comsol A/S

During product development and manufacturing, simulations can take on different tasks such as product optimization, prediction of the behavior of the end product, optimizing and predicting each manufacturing step, and parameter control during manufacturing. Each task has its own set of requirements, and in this talk Thure Ralfs will take a look at some of these requirements and what they mean for the simulation tool.

Thure Ralfs is managing director of COMSOL's Danish office. Before joining COMSOL in 1997, he worked with various technical software. Thure has an MSc and MBA from the Technical University of Denmark.
11:45 - 12:20
ForZDM: A Roadmap to Digital Factories

Davide Caputo, Project Manager, GKN Aerospace Norway

The ongoing ForZDM project (Integrated Zero Defect Manufacturing Solution for High Value Adding Multi-stage Manufacturing Systems) aims at developing and demonstrating a next generation Zero Defect Manufacturing (ZDM) strategy capable of dynamically achieving the production and quality targets grounding on an integrated quality and production control solution for multi-stage systems. The presentation will show the overall concept of the project, providing insights on the challenges of the real shopfloor implementation in the project use cases (medical, aerospace, and rail manufacturing companies) and highlighting possible paths for exploiting the untapped potential of data made available by industry 4.0 technologies.

Dr. Davide Caputo is Senior Project Manager at GKN Aerospace Norway. He is a mechanical engineer and holds a PhD in electrical engineering from Politecnico di Milano. He has been involved in several EU R&D projects and is currently coordinating the ForZDM project.
12:20 - 13:20 Lunch
13:20 - 13:55
ForZDM: Data Gathering and Post Processing within Medical Devices Production

Simone Ferretti, Technical Manager, Montronix S.r.l., Italy

The presentation will introduce the application of monitoring and control strategies in medical components production following the ForZDM paradigm implemented in the extrusion line at the company ENKI for reducing the defect rates. Enki produce medical components, characterized by very high quality requirements and strict validation standards. Polymer high value single-use products find applications in oncology, angiology, angiography, and angioplasty, where the demand for customized and miniaturized products is a significant trend. The production of microcatheters is nowadays challenging and expensive, with a high defect rate (75 %). The presented solution includes a novel data gathering system and a dedicated operator HMI for acquiring process and quality information and identifying the complex correlations between material properties, production environment and the quality of the product.

Simone Ferretti, Technical Manager at Montronix Italy, has several years of experience in machine tool manufacturing, maintenance of electrical systems in production plants and more than 15 years in machine tools monitoring systems and sensors. In the ForZDM project, he has developed the data gathering system of the ENKI use case.
13:55 - 14:30
Tool handling in a Smart Factory

Josef Axelsson, Sales Manager North Europe, E. Zoller GmbH

To minimize setup time and maximize quality, companies work with their tool handling strategy by connecting their different systems from purchase, storage, cam programming, production planning, presetting, logistics and data transfer to their production machines. Different companies have different strategies with different benefits. But they all have the common denominator to connect their systems in line with Industry 4.0. After this meeting, the goal is for you to have information about the strategies and ideas, which will fit your company.

Josef Axelsson is Sales Manager for North Europe for E. Zoller GmbH and has worked with Zoller products for 5 years. During those years, he has seen 300 companies, and how they work with their tools.
14:30 - 14:50 Break
14:50 - 15:25
Towards Zero Defect Manufacturing in Multi-stage, Automated Manufacturing Processes

Roberto Perez, Head of Innovation – New Technologies, GF Machining Solutions, Switzerland

The presentation will explain the state of the art and future progresses in high precision manufacturing of moulds and parts with GF Machining Solutions technologies integrating automated measurement and compensation of deviations as well as machine equipment control through new connected and data driven digital modules.

Roberto Perez holds a PhD in Physics from the University of Geneva (Switzerland) and an MBA from The Open University (UK). He has been working as responsible of research and innovation activities for the EDM Unit of GF Machining Solutions until 2015, and afterwards as responsible of Industry 4.0 and Innovation in the new Digital Transformation Unit of the Division.
15:25 - 16:00
Strategies for Implementation of I4.0 Solutions in the Manufacturing Industry

Patrik Ling, Technical Director, Fanuc Nordic, Sweden

Patrik Ling will give a talk on the challenges of machining factury. These include:
– Preventive maintenance=a factory that does not stop unexpectedly
– Optimization of processing conditions
– Cell optimization-> Factory optimization
– Automate field skills
These challenges can be overcome by actively utilizing AI and IoT by “Connecting, Monitoring, Thinking and Driving in Manufacturing Field.”

Patrik Ling is Technical Director of factory automation with 34 years of experience from CNC machines and robots in areas such as service, application programming, sales, business development and team coordination.
16:00 - 16:10 Closing Remarks

Industry 4.0 Tools: Integrated Modelling and Sensing for Manufacturing, 9 May 2019

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Registration fee
Members of ATV-SEMAPP or other promoting organizations: DKK 2,150
Non-members: DKK 2,775
Early bird discount of DKK 200 when registering before 6 April 2019
Ph.D. students from ATV-SEMAPP member institutions: DKK 975
B.Sc. and M.Sc. student members: DKK 200 (student membership is free of charge).

The fee includes talks, breakfast, lunch, and coffee breaks.


Cancellation
Registration is binding, however substitutions are accepted at any time.


Questions

Contact ATV-SEMAPP by e-mailing semapp@atv-semapp.dk or phoning Jytte Laursen +45 4525 4898 or Charlotte Leser +45 4525 4899.