Production Technology Center - Inmetro · Production Technology Center t l C i I f tFhF raunhofer...

Production Technology Center

F h f I ti Cl tFraunhofer Innovation Cluster

Maintenance, Repair andOverhaul

Markus Röhner

Fraunhofer IPK

WorkshopWorkshop

Innovation and Opportunities

For Cooperative Projectsp j

August 19th 2010

Content

Fraunhofer innovation cluster MROMaintenance, Repair and Overhaul

F h f IPKFraunhofer IPKInnovative Production Technologies

Activities in BrazilActivities in BrazilPartnership, Project Proposal and Research

ContactContact

mroin Energie und Verkehr


Fraunhofer innovation cluster

M i t R i d O h l i E d T tMaintenance, Repair and Overhaul in Energy and Transport

© Fraunhofer



Fraunhofer innovation clusters

Starting point “Pact for Research Starting point Pact for Research and Innovation” between government and research Facilities

Cooperation between science,

universitiesfundamental research

Coope at o bet ee sc e ce,economy and community

To ensure longtime team work and exchange of knowledge in a region

i d t

teamwork

g g g

Acceleration of innovation processes by clustering of resources

S i l t d

Fraunhoferapplied research

industryR&D products

and services

Securing employment and triggering new innovations

© Fraunhofer



»Digital Production« in Stuttgart

Current Fraunhofer Innovation Cluster

»Digital Production« in Stuttgart»Mechatronic Engineering« in Chemnitz»Optical Technologies«, Jena Optical Innovations (JOIN)»Personal Health« in the region Erlangen/Nürnberg/Fürth Magdeburg

Bremen

Berlin

»Nano for Production« in Dresden»Automotive Quality Saar« in Saarbrücken»Digital Technologies for Trucks« in Kaiserslautern

P l T h l i i H ll L i i

Dresden

ChemnitzJena

Halle-Leipzig

d

Aachen

»Polymer Technologies« in Halle-Leipzig

»Virtual Development, Engineering & Training« in Magdeburg»MultiMat« in Bremen»Future Security BW S4« in Freiburg

NürnbergKaiserslautern

Stuttgart

Fürth ErlangenDarmstadt

KarlsruheSaarbrücken

»Virtual Development, Engineering & Training« in Magdeburg

»Adaptronics« in Darmstadt

»Integrative Production Technology for energy efficientTurbo Engines TurPro« in Aachen

Freiburg

»Hybrid light weight Design« in Karlsruhe»Secure Identity« in Berlin-Brandenburg »MRO in Energy and Transport«

in Berlin-Brandenburg

© Fraunhofer



20 % of the total costs of an airline are

Example: Relevance of MRO for Airlines

20 % of the total costs of an airline are MRO-costs. 8 % of operation costs are for the MRO of engines alone

Main costsAssembling and disassemblingCosts of repair of single parts

ann

ove

r

Material costs of replaced components

Example moving blade

Direct operation costs of airlines

Mai

nte

nan

ce H

a

a p e o g b ade

OEMs allow only one single complete overhaulAfterwards replacement of new parts R

up

p, M

TU M

Afterwards replacement of new partsNew part costs approx. 500.000 $ for one set of 1st HDT rotor stageDistribution of engine costs

© Fraunhofer



Technical reasons for MRO-activity

Example: Relevance of MRO for Public Transport

Technical reasons for MRO activityCorrosion and aging of materialsOperational wear and tear VandalismVandalismTechnical advancement (overhaul)

Damage caused by vandalism for Deutsche Bahn“ [2]Damage caused by vandalism for „Deutsche Bahn [2]

50 million € per year ( for 46.000 recognized offences )

Damage caused by vandalism for „Berliner Verkehrsbetriebe“8.9 million € in 2007Removal of graffiti per train: 15.000 €, 2-3 working days needed

Total costs of corrosion in Germany [1]

Approx. 70 billion € or 4 % of GDP without secondary costs[1] Fachhochschule Ostwestfalen [2] Tagesspiegel 1.10.2008

[2]

© Fraunhofer

[2] Tagesspiegel 1.10.2008



Main Challenges

High demand on reliability and availabilityg y y

Decentralization of equipment (e.g. offshore wind turbines)

Different life time expectancy for individual components

Decreasing availability of resources lifetime extension Decreasing availability of resources lifetime extension

New operating schemes:

Fly-by-Hour / Power-by-Hour: Fixed pricing per hour of tioperation,

“guarantied” availability

Fixed Price: Fixed pricing per event

© Fraunhofer



Maintenance, Repair and Overhaul

MRO in Energy and Transport

Maintenance, Repair and Overhaul Goods with high investment costs and long product lifecyclesRevenues from after-sales (MRO) contracts account for a substantial portion of the overall profitpLow level of scientific background, high research demand on MRO techniquesHigh technological and economical potential

Sectors Transport EnergySectors Transport Energy

Railway

Road AviationAero-engines

Wind energy

Stationary Turbines

Solar energy

y gy

Transfer of the technical expertises to other sectors

© Fraunhofer



Partner

Coordination: Fraunhofer IPK Berlin

Research facilities Industry

F h f G ll h ftFraunhofer-GesellschaftInstitute for Production Systems and Design Technology (IPK)Institute for Reliability and Institute for Reliability and Microintegration (IZM)

Technical University of BerlinInstitute for Machine Tools and Institute for Machine Tools and Factory Management (IWF)Institute for Land- and See Transportation (ILS)

Federal Institute for Materials Research and Testing (BAM) New partners from Brazil are

welcome!

© Fraunhofer



Structure and organisation

Approved by the Fraunhofer-Gesellschaft (FhG) Executive Board on 8.12. 2008Approved by the Fraunhofer Gesellschaft (FhG) Executive Board on 8.12. 2008Goals of the Innovation Cluster:

Formation of an internationally renowned, highly component MRO-region in Berlin and BrandenburgKnow-how transfer between the transportation, energy and other sectorsConservation of resources due to the extended service life time enabled by the deployment of enhanced MRO-strategies and technologies

Funding:LOI participating industry: 4.200.000 €LOI states Berlin and Brandenburg: 6 800 000 €LOI states Berlin and Brandenburg: 6.800.000 €Fraunhofer-Gesellschaft: 4.600.000 €

Research and development on MRO Topics by the Fraunhofer innovation cluster Research and development on MRO-Topics by the Fraunhofer innovation cluster MRO in 3 years is funded with 15 600 000 €

© Fraunhofer



Project Forms in the Innovation Cluster MRO

I i Cl j l Fi i f jInnovation Cluster are project cluster Financing of projects

Industrial project :Research by order: Research by order: Subject defined by and project paid by industrial partners, confidentiality

Transfer project:Industriialprojects

Direct applicability

Transfer project:Definition of contents and work plan by R&D-partners and industry, mixed funding with different public portion

Transfer projects

p ojects

Initial research: Interdisciplinary subjects, definition by R&D-partner based on recommendation by i d bli f di bli i f l

Interdisciplinarity

Initial research

industry, public funding, publication of results

© Fraunhofer



Fields of innovation

MRO-Planning and digital assistance

Industrial cleaningCondition monitoring and diagnostics

Repair technologies

© Fraunhofer



Field of innovationCondition monitoring and diagnostics

Nondestructive testing

dCondition monitoring

Residual service life prognostics

Data mining

© Fraunhofer



Bild Challenges

Multisensory Train Wheels Monitoring

Bild ChallengesAutomatic tread surface inspection for train wheelsCyclic monitoring of wear development during train operationEconomical test system for transporting enterprisey p g pSimple installation at the rail trackImprove derailment safety by wear identification Roundness defects due to deformation, wear and slip

ApproachMultisensory measuring by optical and vibration sensor Monitor wheels passing the rail Monitor wheels passing the rail Optical inspection of the wheel arch surfaceExamine rolling noise of the wheel arch surfaceIntelligent combined evaluation and visualization Intelligent combined evaluation and visualization Inspection of geometry, surface, cracking

© Fraunhofer



Field of innovationMRO-planning and digital assistance

MRO-process planning

Service assistance systems

Reverse engineering

Provision of replacement parts

© Fraunhofer



l i f di i di f l d

Reverse Engineering for MRO (COSDiMRO)

Acceleration of condition recording of complex products1. Recording of the geometry

Creation of 3D geometric models2 Identification of the components and parts2. Identification of the components and parts

Part identification and separation inside the geometric model (manually or through the use of pattern matching)

3. Synthesis of the product topology and its structure

ActualActual statestate ofof productproductActualActual statestate ofof productproduct

y p p gyCreation of an assembly from the separated partsDeduction of a product structure to be used in PLM-Systems

Arn

olds

3D3D--Scan modelScan model3D3D--Scan modelScan model

es: A

EG, G

OM

, A

Digital model of the current state of the product forplanning and optimisation of MRO-processes:

Discrepancy determination with respect to the target stateld i f O i h i l h l i

Imag

e so

urce

AssemblyAssembly modelmodelAssemblyAssembly modelmodel

Valdation of MRO-processes with virtual technologiesMRO-processing supported by augmented reality

© Fraunhofer



Field of innovationIndustrial cleaning

Residue-free cleaning

Process automation

Removal of functional layers

Ecologically friendly cleaning

© Fraunhofer



CO2-Blasting within MRO (COSDIMRO)

Challenge Dry und residue-free cleaning technologies required Blasting with solid carbon dioxide fulfils the requirementN i t f l i f ll iti il bl No equipment for cleaning of small cavities available Dry ice hardness limited the area of application

ApproachesApproachesDevelopment of miniaturized blasting nozzles and equipment for dry ice blasting Production of a dry ice blasting abrasive which fulfil different

Draft: High pressure CO2 blasting

Production of a dry ice blasting abrasive which fulfil different requirementsDevelopment of the high pressure CO2 blasting and cutting

Draft: Miniaturized cleaning nozzle (CO2 Snow blasting)

© Fraunhofer



Field of innovationRepair technologies

In Situ conditioning

Process automation

Flexible repair technologies

Innovative cutting materials

© Fraunhofer



Flexible and Efficient Deployment of MRO- Resources (FEMRO)

ChallengesReduction of the scrapping rateQuick response on changing demandsReduction of stock requirements

j iProject topicsReduction of tooling diversity by the formation of tool groupsAdaptive machiningAdaptive machiningModular fixturesMachining of large scale components with ceramic toolsSelective laser sintering of cutting toolsSelective laser sintering of cutting tools

<

© Fraunhofer

<



High Productive Cutting Strategies with Universal-and Combination Tools

Challenges MRO-OperationsSmall production batches high product diversityShort response timeMachining of wear-resistant hard to machine materialsReduction of special tooling costsReduction of stock requirementsReduction of stock requirements

RemedyAdjustment of tool path rather than adjustment of tool j p jgeometryProductivity- und machining quality enhancement by optimization of cutting parameters

d i f li di i b h f i f lReduction of tooling diversity by the formation of tool groups

<

© Fraunhofer

<



Objective of the Innovation Cluster MRO for Transportation and Power Generation“ is to

Objective of the Innovation Cluster

Objective of the Innovation Cluster „ MRO for Transportation and Power Generation is, to

establish the region of Berlin-Brandenburg being internationally acknowledged as a center of

expertise in the field of maintenance, repair and overhaul

Increasing of product safety and reliabilitySaving of resources by increasing the operating time and efficiency of usageefficiency of usageThe cluster initiates first projects; however MRO research is supposed being continued after phasing out of the cluster funding by showing the impact of MRO research programs

Triggering regional, national and international funding programsFacilitating service sites with the internal R&D funding proposals proposals

Establishing an international MRO-Network

© Fraunhofer

Content




ContactContact

Innovative Production Technologiesg

Fraunhofer-Institute Production Systems and Design TechnologyInstitute for Machine Tools and Factory Management of the Technical University Berlin

Production Technology Center

Fraunhofer-Gesellschaft University of Technology Berlin

Corporate ManagementP f D I K M ti

Institute for Production Systems and Design Technology (IPK)

Assembly Technology and Factory ManagementP f D I G S li

y gyInstitute for Machine Tools and Factory Management (IWF)

Virtual Product CreationProf. Dr.-Ing. R. Stark

Prof. Dr.-Ing. K. Mertins

P d ti S t

Prof. Dr.-Ing. G. Seliger

M hi T l d M f t i T h l

Industrial Information TechnologyProf. Dr.-Ing. R. Stark

Automation TechnologyProf. Dr.-Ing. J. Krüger

Production SystemsProf. Dr. h. c. Dr.-Ing. E. Uhlmann

Industrial Automation TechnologyProf. Dr.-Ing. J. Krüger

Machine Tools and Manufacturing TechnologyProf. Dr. h. c. Dr.-Ing. E. Uhlmann

Medical Technology Quality Science

Joining and Coating TechnologyProf. Dr.-Ing. habil. J. Wilden

Joining and Coating TechnologyProf. Dr.-Ing. Michael Rethmeier

gyProf. Dr.-Ing. E. Keeve

Q yProf. Dr.-Ing. J. Herrmann

Micro Production TechnologyProf. Dr. h. c. Dr.-Ing. E. Uhlmann

Fraunhofer IPK

Mission and Goals

Fundamental research and education as well as applied research and developmentO ti i ti f i d t i l f th d t Optimization of industrial processes – from the product idea through to product development, design and manufactureFast transfer of R&D results into practical applicationsFast transfer of R&D results into practical applicationsCost-effective and environmentally friendly solutions for SME

Innovationsfor Industry

Fraunhofer IPK

Facts and Figures

1986 IPK and IWF TU Berlin move into PTZ517 employees (scientists, service and students)More than 70 test areas and 7 special More than 70 test areas and 7 special laboratories on about 7 100 m²Budget of 24,6 Mio. Euro in 2009 Spin offs and start ps b 12 % of Spin-offs and start-ups by 12 % of former staff members

Fraunhofer IPK

Markets and Customers

Mechanical and plant engineering

Aviation industryy

Energy industry

Tool and mould making

Car industryCar industry

Electrical engineering

Software applications

Health care

Our innovative technologies strengthen your Health care

Public institutionscompetitive position

Fraunhofer IPK

Spectrum of Services

Feasibility studies and calculationof profitability

Development of technologies, tools and software systemsp y

Project planning and engineeringManagement of bi- and multilateral projects

Testing with state-of-the-art equipment

multilateral projectsIndustrial projects to prototypical implementation

Training, seminars, coaching

Fraunhofer IPK

Order Processing

Company approaches IPK with an inquiryDefinition of project scheme ⇒ IPK submits an offerPlacing of order (non-disclosure agreement)IPK carries out projectPresentation of results upon project completionp p j p

Specific know-how for individual solutions

Fraunhofer IPK

Cutting Technologies

Development, qualifying and optimization of state-of-the-art and novel cutting

and tool technologies as well as integration in industrial process chains

Scope of ServicesDevelopment of manufacturing technologies and Tools for milling, drilling and turningg, g gDevelopment of machining strategies for new material by use of innovative tool concepts and processesOptimization of single processes and process chains as a whole

F h f IPK

Cutting Technologies

Fraunhofer IPK

ResearchCutting of high performance materials

Development of cutting tools

Development of tooling systems

iProcess strategies

Development of short term testing procedures for the evaluation of cutting meterials and coating systems for cutting tools

Analysis of cutting processes using experimental evaluation and simulationexperimental evaluation and simulation

Fraunhofer IPK

Finishing

Development of manufacturing technologies for improvement of quality and

Efficiency in the field of finishing processes

Scope of ServicesMachining of high performance materials as Ni-basis-alloys, compound materials and mono y pcrystallite materials

conventional grinding technologies as round- and unround grinding grinding of profiles for gears asunround grinding, grinding of profiles for gears as well as grinding of micro milling tools

High speed oscillated planar grinding, high speed planar grinding with planetary kinematicsplanar grinding with planetary kinematics, high precision band grinding, ultrasonic assisted grinding and flow grinding

Fraunhofer IPK

Finishing

Research

Grinding of high performance materials, e.g.Grinding of high performance materials, e.g. ceramics

Development of grinding tools

Development of tooling systems

Process strategies

D l t f h t t t ti d fDevelopment of short term testing procedures for the evaluation of cutting materials

Analysis of finish processes using experimental evaluation and simulation

Fraunhofer IPK

Cleaning and Blasting Technologies

Development of ecological efficient technologies for cleaning of parts and

machines

Scope of ServicesResearch and development for blasting technologies using stable abrasive materials and CO2g 2

Optimization of machinesNew industrial fields of application for innovative cleaning technologiesInitialization and management of the Fraunhofer-Allianz Reinigungstechnik – Cleaning Technologies

Fraunhofer IPK

Cleaning and Abrasive Technologies

A li ti f l i ith lid CO2

Removal of old, disturbing or functional coatings

Pre-treatment before adhesive bonding of metals or plastics

Applications for cleaning with solid CO2

g p

Cleaning of machinery and plants

Applications for cleaning with liquid CO2Different solvent properties

Cleaning of complex part geometries, porous materials and g p p g , pbulk cargo

Cleaning of materials sensitive to temperature or humidity

Fraunhofer IPK

Laser finishing of tools made of ultra-hard cutting materials

Development of an efficient operation for the processing of difficult-to-cut

materials

Mono- und polycrystalline diamond tools as well as tools coated with PCBN and CVD-diamond

Research Topics Laser manufactured chip breaker in a polycristalline diamond (PCD) cartridge

CVD-diamond coatingsmoothed by laser

tools, coated with PCBN and CVD-diamond

Manufacturing of complex geometries into the rake face (chip breakers)

200 µm200 µm200 µm

processing10 µmSharpening of the cutting edge and smoothing of

the rake face

Surface conditioning of the rake and the clearanceSharpening of the cutting edge radius atSurface conditioning of the rake and the clearance

facecutting edge radius at cutting tools with CVD diamond coating20 µm

Measurement Technologies for Production Processes

Appropriation of Information regarding Process and Product from measurement

and testing for the entire production process

Scope of servicesCharacterization of surfacesMeasurement of geometrical dataMeasurement of material propertiesAnalysis and Optimization of ProcessesAnalysis and Optimization of Processes

Fraunhofer IPK

Micro Production Engineering

Reliable and high-value manufacturing with a geometrical accuracy of one

micrometer at the workpiece

Scope of ServicesResearch fields: Technologies, Machines Tool, Measurement Technologies, Processesg ,Development, Manufacturing and Test of Micro Products, micro structured products as well as complex micro systems

500 µm© Fh-IPK500 µm© Fh-IPK 500 µm© Fh-IPK 500 µm500 µm© Fh-IPK500 µm© Fh-IPK 500 µm500 µm© Fh-IPK

Combination of micro manufacturing technologies to complete process chainsDevelopment of machine tools and components f i f t i

100 µm© Fh-IPK 100 µm© Fh-IPK100 µm© Fh-IPK 100 µm100 µm© Fh-IPK 100 µm© Fh-IPK 100 µm100 µm© Fh-IPK

for micro manufacturing

100 µm© Fh-IPK 100 µm© Fh-IPK100 µm© Fh-IPK 100 µm100 µm© Fh-IPK 100 µm© Fh-IPK 100 µm100 µm© Fh-IPK

Fraunhofer IPK

Micro Production Technology

Fields of researchMachine tool development for micro productionultra precise cutting technologieshigh precision cutting technologiesEDM (Die-sinking and Wire-EDM)machine integrated measurement systemsProcess integration of micro technology

Fraunhofer IPK

Structure Analysis

Goal: significant increase of manufacturing accuracy by optimization of the

machines tool structure

ServicesAnalysis of static, dynamic and themal influences on production systemsinfluences on production systemsAnalysis of safety environments and components of machine toolsAnalysis of processes for impulse magneticAnalysis of processes for impulse magnetic forming and joiningAnalysis of interactions between machine and process and the dependencies on the machining result

Fraunhofer IPK

Development and Design

Increase of static and dynamic rigidity with constant accuracy in machine tools

ServicesDevelopment of fiber integrated machine componentsC i i i i f i l lConstructive optimization of single elements, components, as well as complete structuresDevelopment of applications in the field of high speed machining and parallel kinematicshigh speed machining and parallel kinematicsDevelopment of special 6 axis rope kinematic for large scale applications

Fraunhofer IPK

Machine tool integrated measuring and testing

Integration of optical and camera assisted measurement systemsto improve

manufacturing accuracy

ServicesDevelopment and Design of componentsIntegration of camera assisted measurementIntegration of camera assisted measurement and testing functionsCompensation of tool geometry

Content




ContactContact

Activities in Brazil

Partnership for Applied Research in Brazil

i d i l i ( ) lInstituto de Pesquisas Tecnológicas (IPT), São Paulo Prof. Oliveira and Prof. Abackerli

Instituto Tecnológico de Aeronáutica (CCM-ITA), São José dos CamposProf. de Oliveira Gomes

Universidade Federal de Santa Catarina (UFSC), Florianópolis Prof WeingaertnerProf. Weingaertner

Universidade Metodista de Piracicaba (UNIMEP), Piracicaba Prof. Schützer

Universidade de São Paulo (USP), São Carlos Prof. Rozenfeld

Universidade Federal de Bahia (UFBA), SalvadorUniversidade Federal de Bahia (UFBA), Salvador Prof. Lepikson


BRAGECRIM: Brazilian – German Collaborative Research Initiative on Manufacturing Technology

Duration: 10.2009 – 09.2011

Funding Agency:

Germany

Brazil

PTZ Berlin (Fraunhofer IPK and IWF TU-Berlin) 3 BRAGECRIM Projects:

A Quick test Method for the Characterization of In process Properties of A Quick-test Method for the Characterization of In-process Properties of Conventional Grinding Wheels)

Partners (Brazil):

Prof. Dr. Ing. W. Weingaertner LMP / UFSC – Florianópolis


BRAGECRIM: Brazilian – German Collaborative Research Initiative on Manufacturing Technology

Holistic Optimization of Sculptured Surface ManufacturingPartners (Brazil):

Prof. Dr. Ing. K. Schützer SCPM / UNIMEP – Piracicaba

Prof. Dr. Al. J. Abackerli IPT – São Paulo

Prof. Dr. A. LepiksonUFBA – Bahia / Salvador

Remanufacturing Oriented Production Equipment DevelopmentPartners (Brazil):

Prof. Dr. J.F.G. Oliveira undProf. Dr.-Ing. RozenfeldUSP São Carlos

Prof. Dr. F. ForcelliniUFSC – Florianópolis

USP – São Carlos


Project Proposal 2010 in Cooperation with ITA

Manufacturing of components for the Oil and Gas Industry

Coordinator of this proposal: Technological Institute for Aeronautics ITA, Prof GomesProf. Gomes

Other institutes: SENAI-CIMATEC (Integrated Center for Manufacturing and Technology - Bahia)

CEFET RS (F d l I tit t f Ed ti S iCEFET RS (Federal Institute of Education, Science and Technology in Rio Grande do Sul)

Partners from the Industry: Villares Metals (Böhler Group), VSE (Vale do Rio Doce Gasturbinenbau) Maxiforja MaterialiseDoce, Gasturbinenbau), Maxiforja, Materialise (Belgien), Siemens SP, ROMI S.A. (machine tools), ISCAR Brazil and Petrobras, Quaker Chemical

Project Budget: approx R$ 4 5 Mio (approx € 2 MioProject Budget: approx. R$ 4,5 Mio. (approx. € 2 Mio., including PhD grants)

Project Duration: 2 years


Other Activities in Brazil

M k t St d i S P lMarket Study in Sao Paulo

ABIMAQ: Cooperation Agreement

2010: Technologie Workshops in Rio de Janeiro, Sao Paulo and Sao Jose dos Campos

Associação Brasileira da Indústria de Máquinas e Equipamentos


ContactDipl.-Ing. Markus Röhner

Head of Department Manufacturing TechnologyCEO Innovation Cluster MRO

Fraunhofer-Institut für Produktionsanlagen undKonstruktionstechnik IPKPascalstrasse 8-910587 Berlin10587 Berlin

Tel. +49 30 / 39006-279

Fax +49 30 / 3911037

[email protected]

www.ipk.fraunhofer.de

Production Technology Center - Inmetro · Production Technology Center t l C i I f tFhF raunhofer...

Documents

Transcript of Production Technology Center - Inmetro · Production Technology Center t l C i I f tFhF raunhofer...