LEADINGINNOVATIONS

SMART FRAME/ MNSDIAG workshop on Micro- and Nano-systems

Warsaw (Poland) 20.2. – 21.2.2013

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Our Profile

Austria’s no. 1 in applied production research Multidisciplinary team with 85 employees Business locations in Steyr and Vienna 7,7 Mio. EUR turn-over (2011) Since 1995 over 1.240 (inter-)national projects

in industry (970) und research (272)

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Our Mission

The main aim of PROFACTOR is to perform research to increase the competitiveness of manufacturing industries in Europe

All technological developments are based on the premises of resource efficiency and sustainability for the benefit of society

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Our Partners

Global research network Over 400 companies from the field of manufacturing industries:

50% mechanical and plant engineering, 25% automotive, 25% others Many long standing cooperations

… und viele weitere

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Our Topics

Strategic Priorities

Research Priorities

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Overview: Quality Control and Process Optimization

Surface Inspection Inline-Thermography 3D-Completeness Inspection Active Noise- and Vibration-Control

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Surface inspection for die-cast parts / BMW Motoren GmbH

Initial situation Manual quality control is subjective and prone to

errors No documentation of accept/reject decisions

Research approach Developments of new illumination systems

and image analysis software Integration of a fully automatic inspection system

Results Increased automation Automatic documentation of quality Typical defect sizes: about 0.1 mm Typical cycle time: 5-6 seconds (excl. handling)

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Thermography for crack detection / Institut Dr. Foerster

Initial situation Defects and cracks near the surface lead to

problems in later manufacturing steps Research approach

Heat flow is analyzed using an IR camera. Inhomogeneities in the material or near thesurface become visible and can be detectedautomatically

Results The reject rate and energy usage could be

reduced substantially Crack within a few mm under the surface can

be detected Inline-inspection is feasible

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Inspection of CFRP parts/ Benteler SGL + MAG

Initial situation Inspection of fiber directions and detection of

defects in fabric is done manually CFRP material is difficult to analyze with

conventional machine vision systems Research approach

Development of specific illumination andsoftware for image analysis

Use of reflection model of carbon fiber todetect fiber angles

Results Speed up to 1m/s Field of view up to 80mm Min. detectable deflection of fibers < 2°

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Completeness inspection in 3D

Initial situation Completeness of complex assemblies should

be checked automatically Various features cannot be well detected in 2D

Research approach Profile scanners generate 3D point clouds that

are compared with CAD data Measurements and direct comparison with

CAD is possible Results

Robust detection of e.g. plugs that are not securely mounted

Cycle times in the range of a few seconds

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Overview: Adaptive Plug & Produce Systems

Simulation based Design and Optimization Holistic Production Planning and Control Adaptive Planning and Grasping 3D-Machine Vision Assistance Systems

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Optimised Plant Design and System Dimensioning / INGENIA GmbH

Initial situation Time behaviour of processes and their

interdependencies (system dynamics) are not considered in plant design

Research approach Development of discrete event simulation models,

holistic rating models and simulation based optimisation methods

Results Flexible experiment environment to analyse future

shop floor processes fully considering system dynamics Optimisation of layouts and production strategies, bottle

neck analysis, virtual performance tests, avoiding design flaws etc.

Visualisation of the optimised processes Recommendation for an optimised design Maximum resource and system efficiency

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Virtual Ramp-UP / INGENIA GmbH

Initial situation Cost intensive adaption of control software after ramp-

up shall be reduced to minimum Research approach

Development and coupling of a discrete event system models with the real control systems

Testing and optimising the control software using the simulation model as plant emulation

Results Tool for virtual performance tests and to detect

design and software flaws early Reduction of ramp-up time up to 60% Additional benefit: Increasing the system

performance by optimising the software of the control system

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Virtual Commissioning ofManufacturing Plants (FAMUS) / Visual Components Oy

Initial situation After the commissioning of the plants, the 3D

Simulation is mostly not used for further development and controls are programmed from scratch

Research approach Starting from simulated systems (plants), real

control code is generated, tested and validated Results

Systems (plants) can be tested realistically with real controllers (Hardware in the Loop)

Development of (new) control software can be performed simultaneously to system (plant) operation (without interruption of production process)

Downtime for software updates significantly reduced

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Simulation Based Production Planning and Control / austriamicrosystems AG

Initial situation Volatile production is difficult to control due to

highly varying process times and yield, a large number of short time disturbances and a high set-up complexity

Research approach Development of an individually, simulation and

priority rules based production planning and control system

Results Automation of production control Increase of throughput by 20% Decrease of planning effort by 75% Reduction of set-up times by 50% Simulation based prognosis of relevant Key

Performance Indicators

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Handling of Sheet Metal Parts

Initial situation Parts are randomly disposed in a bin and are supposed

to be separated and feed to a post-process in an a-priori known coordinate reference system.

Cycle time is about 10 seconds, accuracy of part deposition is 1.5 mm, intermediate reconfiguration of the grasping position is due to time constraints not possible

High number of variants Research approach

Selection of proper grippers and configurations Robust 3D recognition of parts Dynamic process planning

Results Flexible robot handling system Robust machine vision in the presence of noise, clutter,

and occlusions Robust process planning Collision-free and singularity-free motions

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iRobFeeder – Handling of heavy parts

Initial situation Handling of crank shafts in a high-variant production

environment Research approach

Potential analysis of automation Feasibility study resorting to digital simulation Autonomous and adaptive grasp- and path

planning (3D-object recognition, automatic path planning)

Rapid and intuitive programming of manipulation tasks

Results Automation of processes lacking added value Reconfiguration in a range of minutes Cycle time of about 17 seconds Accuracy of part positioning of post process around

1mm

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Ergonomic CollaborationHuman and Machine (LOCOBOT) / Consortium

Initial situation Reduction of “red” work places

Research approach Solutions for practical division of work between

human and machine, which is realizable with adequate use of resources

Results Improvement of ergonomics through

development of assistant systems Modular design of intelligent hard- and soft-

ware components (e.g. compliant robot arm) Software environment for user-friendly

development of solutions and coordination of component interaction

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Overview: Energy and Added Value Products from Residual Materials

Processes for an efficient use of industrial residuals Measurement services

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Biogenic solid/liquid residues

Initial situation Bio-residues from industrial processes are only

used in small quantities Research approach

Development and optimization of biotechnological processes

Maximization of metabolic capacity of selected microorganisms

Results Energy efficient biotechnological processes

for economical attractive materials, secondary raw materials and energy carriers

Project example Butanol from spent liquor of pulp and paper

industry

Kompetenzzentrum Holz

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Gaseous Residuals → CO2

Initial situation CO2 as greenhouse gas causes problems for

nature (climate change) and significant risks for industry (certificates)

Research approach Development of processes on the basis of

proven technologies (chemical, biological, physical)

Results Efficient processes for CO2 usage

Project example Production of non-corrosive de-icing agents

from cement industry flue gas CO2

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Overview: Functional Surfaces and Nanostructures

Development of high resolution, large area patterning processes(Nanoimprint Lithography and InkJet Printing)

Development of surface coatings and materials for special applications Measurement services

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Process Development for the Structuring of Surfaces

Initial situation Development of new functionalities for products and

devices, increased performance and improve efficiency Research approach

Novel effects and new applications from using of e.g. bionic or nano-effects

Development of processes for micro- and nanostructuring on large areas using Nanoimprint Lithography

Results Cost effective and fast nanostructuring processes

for areas like safety features, biochips, optics Feature sizes 100µm – 10nm Evaluation of suited materials Optimisation of stamp design (homogeneity,

reproducibility of the imprint process)

IMS Nanofabrication

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Material Development

Initial situation Product properties are determined in a large

part by the properties of the surface Research approach

Development of coatings, nanoparticles , nanoimprint materials and functional inkjetinks

Based on sol-gel chemistry Results

Surfaces with tailor-made physical and chemical properties, e.g. 10 times reduced cleaning efforts, increased scratch resistance

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Measurement Services

Initial situation Surface topography (µm, nm) and surface chemistry

determine product properties Quantities to be measured

Surface topography and roughness Layer thickness and refractive index Surface free engery/contact angle of liquids Viscosity of liquids Particle size and particle size distributions in

suspensions Scratch and abrasion resistance

Results Choosing and development of measurement

procedures Analysis and reports