smart factory - agoriamar 03, 2015 · 3/3/2015 11 setup machine mazak integrex 200-iv multi-task...
TRANSCRIPT
3/3/2015
1
Rendabel Metaalbewerken via Nieuwe Technologie
SmartFactory
1 3.03.15 © sirris | www.sirris.be | [email protected] |
Smart Factory
3/3/2015 2 © Sirris | www.sirris.be | [email protected] |
Planning /
Set-up
Simulation
Robot – machine
interface
Ergonomics (machine accessibility
for manual operation)
Production
engineering
Gripper design
Universal local
storage
Robot
programming
Production
Process
monitoring
Tool monitoring
Control
Quality control
3/3/2015
2
Smart Factory
3-3-2015 © Sirris | www.sirris.be | [email protected] | 3
Planning /
Set-up
Simulation
Robot – machine
interface
Ergonomics
(machine accessibility
for manual operation)
Production
engineering
Gripper design
Universal local
storage
Robot
programming
Production
Process
monitoring
Tool monitoring
Control
Quality control
Challenges which are solved successfully in available systems:
Partners
3.03.15 © sirris | www.sirris.be | [email protected] |
Sirris KHLim-ACRO Agoria
Fraunhofer-IPA IWT
4
FMTC Flanders Make
3/3/2015
3
Automated quality control for small series
5 3.03.15 © sirris | www.sirris.be | [email protected] |
Objective
3.03.15
Quality control and feedback loop in an
automated CNC machining cel
Applicable for small series
No additional programming skills required
Fast switching between products
Fit in to existing manufacturing procedures (CAM
programmer, CMM programmer, Operator)
Non-”machine specific"
© sirris | www.sirris.be | [email protected] | 6
3/3/2015
4
Setup
3.03.15
CNC machine:
Mazak Integrex 200-IV multi-task CNC machine
Machine loader
RoboJob IRS-CW
CMM
Mitutoyo Ko-ga-me
CMM loader
Simulated machine loader, Kuka KR15
© sirris | www.sirris.be | [email protected] | 7
CNC-cel demonstrator
3.03.15 8 © sirris | www.sirris.be | [email protected] |
3/3/2015
5
CMM program
3.03.15 9 © sirris | www.sirris.be | [email protected] |
CMM program
Automated quality control for small series
3.03.15 10 © sirris | www.sirris.be | [email protected] |
CMM program
3/3/2015
6
Automated quality control for small series
3.03.15 11 © sirris | www.sirris.be | [email protected] |
CMM program
Tool compensation
Automated quality control for small series
3.03.15 12 © sirris | www.sirris.be | [email protected] |
CMM program
Tool compensation
CMM outputfile
3/3/2015
7
Automated quality control small series
3.03.15 13 © sirris | www.sirris.be | [email protected] |
CMM program
Tool compensation
CMM output file GUI w Operator input
Automated quality control for small series
3.03.15 14 © sirris | www.sirris.be | [email protected] |
CMM program
Tool compensation
CMM output file GUI w Operator input
ISO CNC file
3/3/2015
8
Automated quality control for small series
3.03.15 15 © sirris | www.sirris.be | [email protected] |
CMM program
Tool compensation
CMM output file GUI w Operator input
ISO CNC file Call ISO subroutine
Toolcompensation
3.03.15 16 © sirris | www.sirris.be | [email protected] |
CMM program
Tool compensation
3/3/2015
9
Automated quality control for small series
3.03.15 17 © sirris | www.sirris.be | [email protected] |
Automated quality control for small series
3.03.15 18
No additional programming skills required
Fast switching between products
Fit in to existing manufacturing procedures
(CAM programmer, CMM programmer,
Operator)
Non-”machine specific"
© sirris | www.sirris.be | [email protected] |
3/3/2015
10
Process control for small series
“Signature analysis” applied to a CNC machine
19 3.03.15 © sirris | www.sirris.be | [email protected] |
Objective
Design of a prototype monitoring system for
automated production (machining)
Monitors a production process independently and
signals anomalies
Applicable for small series
Inspired by human operator who reacts on sound
deviations
Allows operator to perform other tasks
Operator is called only in case of problems
3/3/2015
11
setup
Machine
Mazak Integrex 200-IV multi-task CNC-machine
Signals
Microphone (industrial grade)
Start/stop signal from the machine (synchr.)
Acquisition card and software
National Instruments CompactDAQ
Labview
Research on complete workpiece
Different operations:
End face turning, drilling, rough/finish milling, turning en
thread tapping
Selected operations for errors:
Rough and finish milling
Simulated errors:
Breakage (absence) of rough mill
Rough mill with broken off insert
Finishing mill removes more material than foreseen
Used sensor:
Microphone inside machine housing
3/3/2015
12
Research on complete workpiece
Used technique: Spectral analysis
(same for reference and new measurement)
1. Filter one frequency spectrum per time segment of 1/10 second
2. Level average frequency spectrum (in dB) over rolling window of
1 second
3. Filter largest difference between two measurements within a
limited frequency band (40 t/m 280 Hz).
4. Compare this largest difference with two threshold values
(orange/red)
5. Visualize status by means of a traffic light:
(status: green, orange and red)
Research on complete workpiece: spectra
3/3/2015
13
Research on complete workpiece
Research on complete workpiece
3-3-2015 26 © Sirris | www.sirris.be | [email protected] |
https://www.youtube.com/watch?v=x4a4n8n5p5E
3/3/2015
14
Possible future developments
Applied to other signal types, bvb. Vibrations
(accelerometers), current, …
Suppression of background signals during
signature measurements based on active noise
cancelling
Dynamic time synchronisation
Expansion to other anomaly types
More advanced signal analysis
Robust selection of threshold values for new
anomalies
Conclusion
First “proof-of-concept” based on sound measurements on
CNC machine
For the tested anomalies this spectral analysis works robust
and the simulated errors are detected successfully
Interest in new, concrete use cases for further elaboration
of relevant methods
Sound (microphone)
Vibrations (accelerometers)
Current
3/3/2015
15
Smart Factory
3-3-2015 © Sirris | www.sirris.be | [email protected] | 29
Challenges which are solved successfully in available systems: + “proof-of-concept” of process monitoring and quality control:
Planning /
Set-up
Simulation
Robot – machine
interface
Ergonomics
(machine accessibility
for manual operation)
Production
engineering
Gripper design
Universal local
storage
Robot
programming
Production
Process
monitoring
Tool monitoring
Control
Quality control
+32 498 919485
Jan Kempeneers
3.03.15 © sirris | www.sirris.be | [email protected] |
be.linkedin.com/pub/jan-kempeneers/20/12b/38/
@JanKempeneers
3/3/2015
16
http://www.sirris.be
#sirris
http://www.linkedin.com/company/sirris
3.03.15
http://techniline.sirris.be
© sirris | www.sirris.be | [email protected] |