smart frame/ mnsdiag workshop on micro-and nano- systems. profactor.pdf · leading innovations...
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LEADINGINNOVATIONS
SMART FRAME/ MNSDIAG workshop on Micro- and Nano-systems
Warsaw (Poland) 20.2. – 21.2.2013
© PROFACTOR GmbH
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)
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
Our Topics
Strategic Priorities
Research Priorities
© PROFACTOR GmbH
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)
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
© PROFACTOR GmbH
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
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