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1 NEXT GENERATION PRODUCTION SYSTEMS: NEXT Start date:End date: 01 September 200531 October 2009 Duration:4 years Budget:21,745,801 EC contribution:13,999,999.

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Presentation on theme: "1 NEXT GENERATION PRODUCTION SYSTEMS: NEXT Start date:End date: 01 September 200531 October 2009 Duration:4 years Budget:21,745,801 EC contribution:13,999,999."— Presentation transcript:

1 1 NEXT GENERATION PRODUCTION SYSTEMS: NEXT Start date:End date: 01 September 200531 October 2009 Duration:4 years Budget:21,745,801 EC contribution:13,999,999 IP 011815 NEXT Presentación al CENIT eEe

2 NEXT IP 011815 2 OVERVIEW OF NEXT PROJECT

3 NEXT IP 011815 3 Establishing the base of a new generation of autonomous and user-friendly machines that will support a much more efficient and comfortable way of working (e.g. automatic recognition of manufacturing tasks and process conditions). User-centric Autonomous Machine Track 2 Manufacturing Breakthrough Track 3 Designing and building the best process-controlled production machines in the world in terms of performance, productivity and achievable quality (2x - 5x improvement in machine tool productivity, increasing accuracy, higher reliability). Economic Objective Track 4 New ways of doing business in the production machinery sector. Exploring and defining new ways of selling products AND services, new formulae not currently applied related to ownership of the equipment, payment, financing, new organisation models, etc.. Dissemination and Training Objective Track 5 Transferring the research results to interested industrial partners, both users and producers of machines, where training and skill development will be provided. Green Machine Track 1 Radical innovation into environmentally friendly production machines. Consider environmental aspects through the entire life-cycle of machines: use of recycled materials for machine elements, reduction of energy consumption at machine use, zero waste produced, dismantling and recycling of 100% machines, and working in non-pollutant machining processes. OBJECTIVES

4 NEXT IP 011815 4 OVERVIEW OF NEXT PROJECT

5 NEXT IP 011815 5 CRITICAL MASS MERGED 6 EXPRESSIONS OF INTEREST OF FP6 23 PARTNERS FROM 9 COUNTRIES PARTNERS REPRESENT THE COMPLETE VALUE- CHAIN FOR THE EUROPEAN PRODUCTION MACHINERY MULTI-DISCIPLINARY TEAMS ORGANISATIONTYPE FATRONIKTechnology centre (E) ASCAMMIndustrial association (E) BOSCHIndustry – user (D) BUTEUniversity (HU) CECIMOIndustrial association (EU) CESIIndustry (I) CNRSResearch centre (F) CR FIATIndustry – user (I) DANOBATIndustry (E) EPFLUniversidad (CH) FIDIAIndustry (I) HULLER HILLEIndustry (D) IFW HANNOVERUniversity (D) ISITechnology centre (D) ITIAResearch centre (I) KU LEUVENUniversity (BE) KUTXASavings bank (E) CORREA – ANAYAKIndustry (E) ONAIndustry (E) SIEMENSIndustry (D) TEKNIKERTechnology centre (E) WZLUniversity (D) EMCOIndustry (A) ASSOCIATIONS MANUFACTURERS USERS TECHNOLOGY CENTRES UNIVERSITIES FINANCIAL - KUTXA CONSORTIUM

6 NEXT IP 011815 6 EXPECTED MACRO END RESULTS TRACK1 THE GREEN MACHINES: Radical innovation forward environmentally friendly production machines. DANOBAT Grinding machine ONA ONA EDM machine TRACK1 THE GREEN MACHINES: Radical innovation forward environmentally friendly production machines. DANOBAT Grinding machine ONA ONA EDM machine TRACK2 THE USER CENTRIC AUTONOMOUS MACHINE: Breakthrough in usability and machine autonomy. EMCO & CORREA EMCO & CORREA High speed milling machines WZL / BOSCH WZL / BOSCH Gun drilling machine TRACK2 THE USER CENTRIC AUTONOMOUS MACHINE: Breakthrough in usability and machine autonomy. EMCO & CORREA EMCO & CORREA High speed milling machines WZL / BOSCH WZL / BOSCH Gun drilling machine TRACK3 THE MANUFACTURING BREAKTHROUGH: New processes due to a big leap performance and innovative processing methods. FIDIA High speed milling machine for dies and moulds MAG Agile machining centre for prismatic components TRACK3 THE MANUFACTURING BREAKTHROUGH: New processes due to a big leap performance and innovative processing methods. FIDIA High speed milling machine for dies and moulds MAG Agile machining centre for prismatic components

7 NEXT IP 011815 7 TRACK4 NEW BUSINESS PARADIGM FOR MACHINERY: A breakthrough to create value for the production machinery business. Methodologies for business model innovation Business model life cycle evaluation software tool Technical configurator TRACK4 NEW BUSINESS PARADIGM FOR MACHINERY: A breakthrough to create value for the production machinery business. Methodologies for business model innovation Business model life cycle evaluation software tool Technical configurator TRACK5 NEW CONTENTS FOR TRAINING, MARKETING AND DISSEMINATION AROUND PRODUCTION EQUIPMENT. Training methodologies and tools Dissemination of results TRACK5 NEW CONTENTS FOR TRAINING, MARKETING AND DISSEMINATION AROUND PRODUCTION EQUIPMENT. Training methodologies and tools Dissemination of results EXPECTED MACRO END RESULTS

8 8 TRACK1: GREEN MACHINES Radical innovation into environmentally friendly production machines. Consider environmental aspects through the entire life-cycle of machines: use of recycled materials for machine elements, reduction of energy consumption at machine use, zero waste produced, dismantling and recycling of 100% machines, and working in non-pollutant machining processes.

9 NEXT IP 011815 9 GRINDING Demonstrator EDD EDD(Electro Discharge Dressing). Metallic bonded wheels dressed in the machine BENEFITS Power consumption reduced up to 30% thanks to the increased grain exposure in the wheel. Possibility to dress metallic superabrasive wheels in the own machine with medium values of grain size more precision Lower piece cost because the life of the wheel is increased up to 40%. Tool life will be compared to machine life. Applications for hard metal grinding; any application of peeling

10 NEXT IP 011815 10 GRINDING Demonstrator MQL MQL in grinding BENEFITS Energy consumption reduced up to 50 %. Liquid power pumps are eliminated. Less space occupied by the machine, up to 50 %. Production costs reduced because the machine is cheaper (less space needed) and power consumption reduced. No liquid residues are produced

11 NEXT IP 011815 11 ONA Demonstrator (WEDM) Development of high technological WEDM with better environmental behavior INNOVATIONS Improve the Paper Cartridge filter lifetime using a secondary filter washable module Development of Washable filter suitable to treat higher amount of residues (high speed of 300 mm2/min possible)of WEDM machine with integrated high speed cutting generator. Reduce the conductivity of the water dielectric fluid by flowing it through the resins interchange stage. Resin consumption reduction BENEFITS New filtration units will allow reducing the waste generation up to 50%

12 NEXT IP 011815 12DesignManufacture Recycling Use Measure the power, tool and oil consumption and the evaluating the noise and waste Develop a software tool for multi criteria analysis for the design of new eco-efficient processes and drive future improvements GREEM SW TOOL Reduce the energy consumption of movable machine and PKM robots components Machines: light weight materials Robots: choose the correct architecture; use green materials like wood (light weight, easier to recycle, needs low energy request for the production) Study the usage phase of the machine

13 13 TRACK 2: USER-CENTRIC AUTONOMOUS MACHINE Establishing the base of a new generation of autonomous and user-friendly machines that will support a much more efficient and comfortable way of working (e.g. automatic recognition of manufacturing tasks and process conditions).

14 NEXT IP 011815 14 EMCO E900 / CORREA RELEVANT INNOVATIONS Automated identification of friction and acceleration behaviour using trace functionality and Extended Trace Capability Implementation of faster setup and calibration services Integration of machine model within tool path planning ( machining time up to 50%) Implementation of an adaptive control that allows monitoring the surface roughness online Implementation of a CUTOPT model-based surface roughness monitoring in milling operations Implementation of an indirect thermal compensation Implementation of a wear detection software for guide ways Compensation WZL KU Leuven

15 NEXT IP 011815 15 EMCO E900 / CORREA BENEFITS More reliable manufacturing processes Higher accuracy of produced goods Reduction of reject rate Reduction of production costs Less maintenance services Compensation WZL KU Leuven

16 NEXT IP 011815 16 Gun Drilling Demonstrator Development & validation of 3D simulation models (Bosch, CRF, WZL) Rotating actuator system for gun drilling (Nora, WZL) Adaptive Control in gun drilling (Bosch, WZL) Workpiece Gundrill INNOVATIONS Development and implementation of an adaptive control system of the process to achieve an optimum performance Development and implementation of a rotating actuator system for gun drilling Development & validation of 3D FE simulation models Sep up of cutting simulation models for automotive application machining

17 NEXT IP 011815 17 Gun Drilling Demonstrator BENEFITS The use of an adaptive control in gun drilling allows increasing the productivity and the process reliability. As process behavior changes significantly during manufacturing, and adaptation of controller parameters is essential to achieve the optimum in performance. The objective is to machine at the tools load limit. For Bosch large scale injector pipe manufacturing is the main field of application while CRF is mainly interested in drilling crankshafts The simulation contributes a quick analysis of tool load limits whithout raising test costs. The availability of production machines increases as initial tool tests can be reduced or generally avoided.

18 18 TRACK 3: THE MANUFACTURING BREAKTHROUGH Designing and building the best process-controlled production machines in the world in terms of performance, productivity and achievable quality (2x - 5x improvement in machine tool productivity, increasing accuracy, higher reliability).

19 NEXT IP 011815 19 High Speed Milling Machine for dies&moulds machining – FIDIA

20 NEXT IP 011815 20 High Speed Milling Machine for dies&moulds machining – FIDIA BENEFITS Improvement in productivity of about 10% is the target related to the implementation of knowledge and process-related algorithms in an open architecture framework, contributing with a 4% revenue increment in selling CNC (over 300.000 in two years) Improvement in performance of about 10-15% by using light weight ram (Al-foam, CFRP) with a ram cost increase of 30% (2.000 against 1.500 ) Improvement in performance of about 20% by implementing a thermal compensation system based on FBGs with a ram cost increase of 50% (fibers + reading unit) (machine cost increase of 5- 7%) The implementation of innovative and easy-to-apply methods will allow for performing ECO-impact analysis on machine tools with time and costs which are suitable and tailored to such application

21 NEXT IP 011815 21 Agile Machining Centre for Prismatic Components - MAG INNOVATIONS Modular design: Configurability of wide range of machine variants by using a smaller number of common modules and components Model based temperature compensation in order to avoid the loss of accuracy caused by thermal influences Compile cycles for advanced control in order to get exact and fast positioning of heavy mass Set-up and calibration service in order to decrease the setup time of a 5 axis machine Energy saving program Optimization of high performance cutting

22 NEXT IP 011815 22 Agile Machining Centre for Prismatic Components - MAG BENEFITS Reduced investment costs Reduced warm up time and increased accuracy Faster and more exact positioning Faster set-up time Increase material removal rate

23 23 TRACK 4: Economic objective New ways of doing business in the production machinery sector. Exploring and defining new ways of selling products AND services, new formulae not currently applied related to ownership of the equipment, payment, financing, new organisation models, etc..

24 NEXT IP 011815 24 New business models

25 NEXT IP 011815 25 New business models INNOVATIONS Consultancy methods, contents and tool for business model innovation of manufacturing companies Business model life cycle assesment software Technical configurator

26 NEXT IP 011815 26 New business models BENEFITS Consultancy methods, contents and tool for business model innovation of manufacturing companies They enable high-level consulting in the fields of customer- oriented business model selection and in adapting organizational structures to the newly arising requirements will be offered to machine tool building companies Clear and structured methodology for strategic innovation Decision support systems to assist strategic decisions: a)Cooperation scenarios preliminary selector; b) Financial guidelines; c) Organizational guidelines

27 NEXT IP 011815 27 New business models BENEFITS Business model life cycle assesment software Evaluation of the economical and environmental performances deriving from the adoption of an innovative business model with respect to the actual one. It permits to quantitatively evaluate the impact of innovative cooperation options between supplier and customer/business partners and of unconventional financial models. Focus not only on machine tool, but on the whole production system Customer/supplier win-win situations for the competitiveness of the whole manufacturing system and not only of some of its actors

28 NEXT IP 011815 28 New business models BENEFITS Technical configurator Supports the search, selection and configuration of machine tools and manufacturing systems, calculates system attributes (e.g. cost, space occupation, MTBF, MTTR) needed by LCA, and visualizes the 3D models of the configured machinery. Allows more efficiency in offers preparation, a higher probability of their success,and a professional technical- commercial approach that will attract customers. Customers will be more involved during the definition of the manufacturing system that should fulfill their industrial need. They will have the opportunity to consider technical aspects in advance and to make a better choice. More than one technical alternatives will be configured and evaluated, so that the guarantee that the system will be effective will be higher.


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