INTEGRATED INDUSTRYJAYESH C S PAI

Integrated Industry

Key challenges of the fourth industrial revolution – such as achieving universal standards for machine-to-machine communication, maintaining data security and finding new business models – can be mastered only through collective endeavor in networks.

The Factory of the Future is intelligent and fully networked. Conventional Mechanical Engineering meets IT, creating

new worlds. Specific Solutions for Integrated Industry are available.

Industrial Companies and Private Individuals can generate their own power supplies and sell their surplus power on a decentralized power supply system.

So in Integrated Energy Grids, the traditional power companies are not the sole stakeholders.

Decentralized Energy Supply

Smart Grids

Factories can meet their internal energy requirements

through miniature heat and powerplants. Surplus can sold in real time

using smart grid.

Smart Energy Storage System

By 2020 10x more Li-Ion storage systems will be installed in Electric Vehicles than in 2016

E Mobility

Toyota bets the future car will be fuelled by hydrogen

Depending on utilization, Smart factories will supply themselves autonomously and dynamically with electricity, switching providers depending on utilization.

An individual mix of wind, hydroelectric, solar and Biogas will improve Industrial economy and make it greener.

Salt River Project (SRP), a utility serving over 1 million homes and businesses in and around Phoenix, Arizona, has connected its power plants and electrical grid to SmartSignal, GE software that can monitor turbines, generators and other machines and minimize unplanned downtime. This is important because like an undiagnosed illness leading to hospitalization, unplanned downtime is expensive.

The world’s power plants could save some $80 billion annually if they operated near their potential

Application Specific Research

Plant based raw materials are rendering crude oil useless for producing plastics.

Application Specific Research In materials research, organic materials are replacing established

materials bacteria and enzymes

are being used industrially

Autonomous Driving

Virtual Product Development

Emotional Engineering

Virtual Reality Systems with Mechanical CAD and ECAD

Tools for mechanical CAD and E-CAD are already networked with virtual reality systems.

Plans designed using these systems can be processed immediately

3 D simulation of component and product models is becoming increasingly diverse and,

Makes sense for more and more applications From tiny screws to complete factories.

Smart Glasses & Gesture Control

Additive Manufacturing

Additive Manufacturing Batch size 1 approach Saves time and costs in Manufacturing Even components and goods which could not be produced with

traditional methods can now be manufactured Range of materials is also virtually unlimited.

Product Lifecycle Management Manufacturing companies now digitize every part of their value chains PLM reduces development times with integrated demand management

and supports innovative system and smart engineering approaches PLM can integrate seamlessly with ERP

Energy Recovery

Process Technologies More efficient way of manufacturing _ Conventional Production methods

Real Time Monitoring & Control

Sensor Technology Thousands and thousands of measurement systems and control

components with sensor functions are taking over factories – a key foundation for full networking

Powerful Joining Technologies Increasing requirements on joints in combination with new materials and

materials combinations in many high-tech branches have led to a situation where adhesive bonding becomes the preferred joining method.

Powerful Joining Technologies push the strength and stability properties of conventional and new material's to their limits.

Rotor for an electric motor with bonded magnets

Industrial Image Processing Whether for inspection and quality assessment, gap measurement ,

position sensing for robots or simply for scanning codes – IIP has gained a foothold everywhere

Camera and laser technologies work with innovative software and can find even as-yet unknown deviations and errors using neural networks.

Light weight Construction New materials and new productions methods with the accelerated

search for more efficient components are helping light weight construction

Carbon and graphene are creating a revolution Most promising future use of graphene is in the production of

lightweight, yet super strong composite materials. Carbon nanotubes are just layers of graphene wrapped into perfect

cylinders. Carbon nanofibers are also made from layers of graphene, this time arranged into the shapes of stacked cones, cups, or plates.

Bionics The study of mechanical systems that function like living organisms or

parts of living organisms.

Smart Materials

Materials Harder than steel but lighter than feathers Self Healing components Programmable materials, Shape Memory Alloys

Adaptronics (Smart Structures) Adaptronic structures and systems can adapt automatically to variable

operating and environmental conditions through the use of feedback control.

Smart Textile Materials

Machine Machine Communication

M2M communication is an important aspect of warehouse management, remote control, robotics, traffic control, logistic services, supply chain management, fleet management and telemedicine. It forms the basis for a concept known as the Internet of Things (IoT).

Smart Factory

Manufacturing systems share production data with systems : every element in intelligent factories is networked with every other element.

Smart Connected

Drive Components Innovative, efficient electric motors, pneumatic systems and more

versatile drive components are becoming essential elements of the automation arms race.

This is equally true in bulk goods production and the process industry.

Predictive vs Proactive Maintenance

Human Machine Collaboration

Robot Co-Workers

Smart Robots - Cobots Cobots which are networked with one another not only automate

processes, they already work safely hand in hand with humans.  They are aware of their environment, utilize advanced sensor

technology effectively (for example 3D vision) and are powered by smart software.

Smart robots can adjust their motion to changes in the surroundings, for example products which are placed differently or are shaped differently. 

Autonomous Transport Systems

Intelligent Drive Technology

Industrial Internet of Things

Industrial Internet of Things

Process Automation Companies in the process industry must innovate constantly to remain

competitive. They strive to reduce plant costs and need to fulfil stricter

environmental guidelines.

Cyber Security Who actually owns the data in the Internet of Things? How can I keep hackers at bay? Do I need to amend patent laws? How is labour law affected when machines and humans work together. Who is liable when smart factories make mistakes?