1/8 Zoom 2018

ZOOM 2018

Industry 4.0: digital technology in microtechnology An autonomous production unit in operation

In 2011, fearful of being dethroned by competition from GAFA, German industry leaders

launched the 4th industrial and social revolution based on a digital transformation of the

industrial model called “Industry 4.0”.

With the advent of digitisation, industry is becoming an interconnected global system in which

machines, systems (ERP) and products communicate non-stop.

Industry 4.0 consists of connecting the Internet of Things and the Internet of Services. The

goal is to increase productivity with zero defects guaranteed, to produce small series within

the same times and costs as mass production series.

With this approach, as soon as an order is accepted, the entire supply chain process is set in

motion. ALL participants and departments from design to production must be interconnected

and work consistently and effectively, thus drastically reducing time lags between the various

technical operations.

The 2018 Zoom event will show that this revolution, which is having a big impact on large

groups, should not be restricted to these groups, but should also impact the industrial fabric

of SMEs and even SOHOs.

This is why Micronora wanted to present an autonomous production unit in operation

including:

- a design station

- a machining station

- a control station

- a 3D manufacturing station

- an assembly station with a collaborative robot

- a laser marking station

The stations are connected by an automated guided vehicle (AGV) equipped with a robotic

arm, saving time between each station.

The supervisory software controlling the AGV ensures the connection between the Internet

of Things, and in part, with the Internet of Services.

2/8 Zoom 2018

The operations take place as follows:

Creation of an original object combining two technologies (machining and 3D printing).

- AJ Solutions (SOLIDWORKS environment) designs the 3D object on a computer and

sends the file to the Willemin-Macodel 701S high-precision machining centre.

- The created object is placed by a machine-integrated robot onto a tray that is given to

Stäubli’s HelMo AGV, which is the real backbone of the APU, transferring the objects

without any time lags. This mobile robot sets the pace for the entire production,

transporting objects from one station to another.

- The quality of machining is controlled by Alicona's advanced InfiniteFocusG5 surface

metrology system.

- The object’s 3D file has also been sent to Frenchmakers’ 3D printers, which create the

resin objects.

- A QR code is laser engraved by IMI Group subsidiary Laser Cheval’s LEM Quartz on the

machined object to download all the information about the equipment presented.

- The two parts (machined object and resin object) are assembled by ABB’s collaborative

robot YuMi, an icon of Industry 4.0.

- The finished object is then given to the visitor.

- With the AGV, the object is created in just 10 minutes thanks to extensive engineering

work by MC Robotics and its Kactus software.

This flexible, highly digitised and automated production unit

can be adapted to different industrial processes

without any major investment

and without extensive changes to the system in place.

Through this event,

Micronora wants to encourage SMEs and SOHOs

to modernize their production equipment

and help them to join the industry of the future.

Video: https://www.youtube.com/watch?v=3MrT_c5jDtE

3/8 Zoom 2018

Zoom 2018: APU, who does what?

AJ Solutions: design/manufacturing and manufacturing simulation software

From preliminary design to manufacturing simulation via

product development, AJ Solutions is the first building

block of the APU. “The SolidWorks tools used will cut the

product development cycle by optimising the different

design stages”, explains Thomas Castalan, business

engineer at AJ Solutions. “At the Zoom, we will create a

typical design providing solutions to the problems of today

and tomorrow's manufacturers”. Distributor and

authorised training centre for the SolidWorks

environment, AJ Solutions helps the users of its services to

optimise the product development process. With new features in 2018, including innovative

topological study solutions integrated into SolidWorks Simulation Professional 2018,

companies optimise their parts to obtain the minimum weight for a given amount of rigidity.

The new Manage tool provides a powerful solution for project management. SolidWorks

Composer enables you to quickly create product animations and graphics from existing 3D

models with assembly instructions, printed marketing brochures, technical illustrations,

interactive animations or training materials.

Willemin Macodel: machining

The 701S machining centre designed by Willemin-

Macodel’s engineers will provide fast and ultra-precise

part machining at the Zoom. “This 3-axis machine with

parallel kinematics is part of a flexible manufacturing

line, computer-managed in real time”, says Bertrand

Decloux, head of sales in France at Willemin-Macodel.

“It enables fully-automated production of various types

of objects and in varying quantities. Its tool and parts

magazine solves planning and scheduling problems”.

The 701s machine is the first machining centre to make

use of the dynamics and rigidity of Delta-type

kinematics. Packed with innovation, the machine offers

the technical features essential for micromachining

applications. The ultra-high-performance powered

spindle was created specifically for harmonised use with

the kinematics of the 701S machine. The tools are

attached directly onto the powered spindle without a tool holder. Its maximum rotation speed

is 80,000 rpm.

www.ajsolutions.fr

www.willemin-macodel.com

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Stäubli: the mobile robot system

Setting the pace, the HelMo robot developed by

Stäubli will physically connect the different

workstations of the Zoom APU. To do so, it will

communicate with each apparatus on the

production line. This innovative system can move

and navigate autonomously. It monitors its

environment continuously using three integrated

laser scanners. This robotic system can perform

fully-automated tasks at a high speed or, if

necessary, work alongside human operators.

HelMo’s design is based on a standard TX2 robot.

The six-axis TX2touch 90L has a maximum load

capacity of 15 kg and a range of 1,200 mm. This

cutting-edge solution enables direct human-robot

cooperation. To meet stringent technical safety requirements, Stäubli’s system has a complex

safety package and a CS9 safety control system. Another distinguishing feature of this robot is

the Safety-Skin, a surface protection system that is touch-sensitive and stops movement

immediately in the event of direct contact with a person. All safety features are certified and

meet the strict requirements of safety category SIL3-/PLe. “The mobile robot system is

modular and has an automatic toolchange system”, explains Jacques Dupenloup, sales

manager for France and Benelux at Stäubli. “That allows HelMo to be used for a wide range of

purposes, enabling it to take on tedious tasks for staff. It can be seen more as an assistant who

is always there when you need it. This is an illustration of the evolution of industrial robotics,

which will become ever more mobile”.

Alicona: control-measurement

At the APU’s quality control station for Zoom 2018, Alicona will

showcase its most advanced surface metrology system,

InfiniteFocusG5. Thanks to its focus variation technology, it can

measure roughness and shape with the same system. The

range of measurable surfaces and materials is practically

infinite thanks to dual coaxial and annular LED lighting. The

user achieves high resolution measurements and connectable

and repeatable results. All surface characteristics are

measured using a single multifunctional sensor. The optimum

measurement parameters can be set entirely automatically.

Multi-user and multi-setting use for different materials and applications is easy to set up. “The

speed of the measurement combined with the absence of contact with the workpiece and the

possibility of measuring on steep inclines are valuable advantages for production inspections

on machined parts”, explains Anne Calvez, manager of Alicona France. “Our systems can be

used on the production line or integrated into a machine tool to be interfaced in an 4.0

industrial process”.

www.alicona.fr

www.man-and-machine.staubli.com/helmo/

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FrenchMakers: 3D printing

Zoom 2018 will exhibit a continuous part production system

using FDM (fused deposition modelling) integrated into an

automated assembly to form an autonomous manufacturing

unit. The parts produced are temporarily stored and the

software that supervises the APU is notified when they are

available. The software then ensures that they are collected

and sent to an assembly robot. “Additive manufacturing is

increasingly popular and offers companies not only a rapid

prototyping method, but increasingly, a production capacity

for parts”, explains Vincent Rousset, director of FabLab in

Besançon. Customizable, these parts can be produced in small

and medium series. FrenchMakers sells all products and materials for 3D printing, provides

training and maintenance, and manufactures prototypes under subcontracts. Through its

expertise in software tools and additive manufacturing equipment, the Besançon company

has developed its own tools to meet the needs of its customers: specific 3D printers,

management of 3D printer farms, automation of everyday tasks, etc. It creates a complete

digital manufacturing ecosystem for professional and corporate “makers”.

Laser Cheval: laser engraving

The subsidiary of the IMI group will contribute to the Zoom APU with

the LEM Quartz laser marking machine, which will laser mark a

Datamatrix code on the machined part deposited on the work tray by

a robotic arm. The LEM Quartz is a precision micro-machining

machine with an automatic door. “It can integrate all the laser

marking systems in our range, from 150 picoseconds (short pulses) to

200 nanoseconds”, explains Dominique Cilia, director of Laser Cheval.

“With this type of source, the engraving and micro-machining quality

is improved: the finish is flash-free on brass and there is almost no

oxidation on stainless steel”.

With a floor space requirement of just over 0.5 m2, this equipment is

packed with features. It has a granite bench for stability, a work tray

measuring 400 X 600 x 50 mm, and a 5-axis system (3 mechanical axes

and 2 optical axes for the laser beam). This enables greater precision

when moving parts and an automatic visual resetting system to

optimally position the laser beam on workpieces.

With this latest-generation technology, users have an efficient multifunctional tool. Virtually

all applications are possible on all metal materials and many plastics, composites and

ceramics. A wide range of operations are accessible: all types of marking for decorative

purposes, identification (barcode, Datamatrix, etc.) and referencing purposes, but also 2D or

3D machining, replacing traditional mechanical or chemical methods. The machine is

extremely easy to use (no specific tools, easy programming) and has an intuitive

human/machine interface.

www.lasercheval.fr

www.frenchmakers.com

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ABB: robotic assembly

A pioneer in collaborative robotics, ABB will present its

YuMi (You and Me) two-armed robot at the Zoom event.

“Able to work safely side-by-side with humans on the

same tasks, YuMi can handle any object with such

precision that it can thread a needle”, says Guillaume

Pradels, head of collaborative robots at ABB France. “It

meets the new needs of users assembling small parts,

with higher production volumes and shorter product life

cycles and production times, and the growing product

customisation trend (especially in electronics)”. This

two-armed collaborative robot has flexible hands, a universal part feeding system, integrated

vision and state-of-the-art trajectory management. During the Zoom it will assemble the metal

and plastic parts of the object to be manufactured by the APU.

MC Robotics: APU engineering and supervision

This Besançon startup engineered and supervised the APU. “MC

Robotics will present its new robotic software solutions at this

mini production plant”, says Mathieu Charles, president of the

company. “The major advantage of Industry 4.0 is that you can

retrieve production data to use it more efficiently. In an era of

collaboration between humans and machines, we believe that

to collaborate more efficiently, the machine must adapt to the

human”. MC Robotics develops industrial user interfaces as

practical and fun as a smartphone interface. “This production

line was entirely integrated and simulated on our Kactus

software to confirm its feasibility”, the specialist adds. “That

means you will be able to observe several different brands of

equipment working in perfect harmony. They communicate,

exchange data and question each other without the operator realizing the amount of

information being exchanged. Today, what is more difficult than getting several different

brands of machine to communicate with each other? The time needed to develop an industrial

solution of this type must essentially be spent on developing the process rather than on

establishing communication between the different elements”.

www.mcrobotics.com

http://new.abb.com

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ZOOM ORGANISATION

On the central island

- Autonomous Production Unit (APU)

In the surrounding area

Predictive maintenance

Femto-ST Research Institute

Today's industrial equipment has sensors creating a massive

flow of data that is difficult to fully leverage. One of the major

challenges for factories in the future will be to give meaning

to all this information.

The Prognostic and Health Management team at the Femto

ST Research Institute is developing innovative approaches for

predictive maintenance based on mathematical tools and

artificial intelligence technology. These research projects are

perfect examples of the Industry 4.0 concept.

Robdec - Cutting workshop robotization

Cetim / Process Industrie / MC Robotics / S.mart / PerfoEST

Goals

To propose a robotic cell for loading/unloading reworking

presses

Mobile, flexible and a rapid return on

investimentguaranteeing operator safety

Solutions

- A modular "architecture" with 1 or 2 robots

to adapt to cycle time requirements

- An architecture including sub-assemblies

that can be easily moved and quickly adapted

to the different machines in the workshop

- A flexible part feeding system using a conveyor,

vision sensor and LED lighting

- Safety partially achieved by a dual zone laser scanner

avoiding the need for guarding

around the robot

- Interface with the presses without changing the control or its safety features

- A programming tool separate from the robot and based on a Grafcet-type model

to facilitate programming by operator-setters

www.femto-st.fr

zerhouni@ens2m.fr

www.cetim.fr

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Aeroμtech cluster

A major industrial sector at the forefront of the 4.0 industrial revolution

The Burgundy Franche-Comté aerospace and defence cluster, launched a little over a year ago,

already has more than thirty members. Having become a leading force, these companies, will

be first-time exhibitors at the Zoom in 2018 under the name Aeroμtech.

“The aim of this cluster is to foster the right conditions for successful innovation projects, the

development of sales activities, the creation of new companies in the region and the

international visibility of local operators”, enthuses Thierry Bisiaux, president of both the

Cluster and the Cryla Group, and a fervent supporter of this thriving partnership. “It is all about

being included in a fertile network of companies that are recognised internationally for their

expertise”.

The cluster is an organisation managed by a steering committee and supported by thematic

working groups led by member companies. “This helps to endorse innovation projects in these

areas, find funding and build strong ties between companies, research laboratories and

training organisations”, says Malua de Carvalho, general representative of Aeroμtech. The

ability to meet all the needs from A to Z of prime contractors in aerospace and defence is the

key asset of these subcontractors, who have purposefully tailored their equipment and

organisation.

A member of GIFAS

Fully immersed in the French aerospace industry, the member companies have greater

visibility of the supply chain.

The cluster is the region’s preferred partner for the creation and management of major

programmes in the sector, such as the Industrial Performance Programme, whose project

manager is France’s aerospace industry association, GIFAS. Regional companies therefore

benefit from the financial support of the region and the industry to participate in a

programme. The aim of the programme is to help them achieve the industrial excellence

needed to meet the challenges of the growing production of civil aircrafts that comes with the

sharp increase in air traffic expected over the coming years.

Supported by Zodiac Aerospace

Involved in the working groups, the members attend networking meetings, market

information days, trade fairs, international missions and conferences organised by the cluster

with the strong support of Zodiac Aerospace - Besançon, by way of Cyril Magnin, production

manager and vice-president of the cluster.

The Micronora trade fair is an excellent opportunity to showcase the dynamics and expertise

of Burgundy Franche-Comté companies on the aerospace market.

Conference

Aeroμtech will organise a conference on 26 September, during which it will present the

challenges of the future aerospace industry and the progress of the Industrial Performance

Programme, in the presence of representatives of the GIFAS Aero SME committee.

www.aeromicrotech.com

m.decarvalho@polemicrotechniques.fr