Industry 4.0 Tools

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.

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.

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.

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.

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.

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.

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.

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.”