Creating Future Powertrain Manufacturing Capability: An ... · Creating Future Powertrain...
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Creating Future Powertrain Manufacturing Capability: An Automation Perspective
P f R b t H iProfessor Robert HarrisonHead of Automation [email protected]
An academic department ithin the science fac lt of a
WMG ‐ An IntroductionAn academic department within the science faculty of a leading UK university
Established in 1980 to facilitate technology transfer and knowledge creation for Industry
750+ people (university and industry) working in 5 buildings (with funding further new buildings)
Professor Lord Bhattacharyya
Training over 2,500 individuals in the UK and abroad (covering Engineering Business Management to Manufacturing Engineering ‐ school to post experience)
yy
Founder and Chairman of WMG
Manufacturing Engineering school to post experience)
Co‐located with Tata Steel, Jaguar LandRover, & Tata Motors European Technical CentreMotors European Technical Centre
One of the seven HVM Catapult centres.
© Automation Systems Group, WMG, University of Warwick, 2014
WMG FaciltiesI t ti l M f t i C t• International Manufacturing Centre
– Automation Systems, Digital Lifecycle Management, International Comparisons
– Materials & Manufacturing- Light-weighting , Materials Processing, g g g g , g,– Sustainable Materials , Metrology
• International Digital Laboratory– Digital Healthcare with Warwick Medical School– Cybersecurity, Experiential Engineering, Medical Informatics, Visualisation– Business focused automotive research
• International Automotive Research CentreB tt Ch i t d E I ti C t E & El t i l– Battery Chemistry and Energy Innovation Centre; Energy & Electrical Systems
– Virtual Engineering and Prototyping– Commercialisation
• International Institute for Product and Service Innovation– Multifunctional Systems , Nanotechnology– Business Transformation and Service Science– Small Firms Centre
• Engineering Management Building– Professional and Executive Programmes
© Automation Systems Group, WMG, University of Warwick, 2014
NAICNational Automotive Innovation CampusNational Automotive Innovation Campus
£100m investment from Government (£25m) and industry.
33 000 2 f ll b ti R&D33,000 m2 of collaborative R&D space.
© Automation Systems Group, WMG, University of Warwick, 2014Artist’s Impression
NAICNational Automotive Innovation Campus
Lead research addressing the long‐term industry‐led strategy of the UK Automotive Council.led strategy of the UK Automotive Council.
Drive the UK Automotive resurgence, sustaining jobs, anchoring suppliers, attracting new suppliers,
bl h d d lenabling major growth and increased employment in the sector and beyond.
Collaborate with centres in the US, Europe, Japan,Collaborate with centres in the US, Europe, Japan, India and China and facilitate high value add inward investment with global Tier 1 suppliers moving to the UK and repatriation of supply h ichains.
A symbiotic relationship between academia and industry will link science, engineering andindustry will link science, engineering and enterprise; co‐locating staff from WMG and Warwick, other Universities, SMEs and suppliers.
© Automation Systems Group, WMG, University of Warwick, 2014Artist’s Impression
WMG Academy for Young Engineers
Education and TrainingWMG Academy for Young EngineersUniversity Technical College based on the edge of the campus (14+) opening 2014Undergraduate Engineering DegreeWMG staff members deliver ~25% of the Engineering MEng/BEng Degree Courses inWMG staff members deliver 25% of the Engineering MEng/BEng Degree Courses in partnership with the School of Engineering Undergraduate Applied Engineering DegreeStarting September 2013 – 4 year Part‐time undergraduate degree leading to a BEng inStarting September 2013 4 year Part time undergraduate degree leading to a BEng in Applied Engineering with specialisation during years 3 & 4.Full Time Masters & Part Time Professional Programmes12 full time courses (technical and non technical) + Foundation, Award and certificate courses Technical Accredited Scheme Masters level modules in low carbon, electronics and software technologies network of HE centres of excellence in key technologies managed by WMG.International Doctorate CentreEPSRC‐backed Doctorate combines academic and industrial expertise, offering industry‐l t h d t htrelevant research, and taught courses.
PhD ProgrammeTraditional 3‐4 year PhD programme.
© Automation Systems Group, WMG, University of Warwick, 2014
Automotive Research
Digital Lif
Sustainab
Design
Forming
Joining
Performa
Simulatio
Electroch
Energy an
Autom
at
Materials
Business
fecycle Ma
bility
ance
on hemical En
nd Electric
ion
s Processi anageme
ngineering
cal System
ng
nt
g ms
Materials: Steels
Materials: Light Alloys
Materials: Composites
Systems: BIW, Chassis, Powertrain
Systems: Hybrid, EV, Electrical
© Automation Systems Group, WMG, University of Warwick, 2014
Creating Future Powertrain ManufacturingCreating Future Powertrain Manufacturing Capability: An Automation Perspective
• Education and trainingT hi d t d t j t– Teaching and student projects
– Physical demonstrators (legacy, current-best, future)
• Research and developmentResearch and development– Future methods, tools and technologies
U d i li ti i i– User-driven applications engineering
© Automation Systems Group, WMG, University of Warwick, 2014
Automation Systems Group
• Currently ten researchers expanding
y p
• Currently ten researchers, expanding• Moved to WMG from Loughborough in Spring 2013
E l t ti t ti it• Example areas automation systems activity• Engineering lifecycle support• Supply chain integration• Supply chain integration• Knowledge capture and reuse• Energy consumption modelling• Process/Machine optimisation• Control system deployment
• User-Driven Collaboration
© Automation Systems Group, WMG, University of Warwick, 2014
Industrie 4.0
© Automation Systems Group, WMG, University of Warwick, 2014
Automation Systems Scopey pVirtual Commissioning
Automation Systems
Web Services and SoA
Maintenance
Energy
Weather
Production Demand/Supply
Automation Systems Workbench
Runtime Control
Lifecycle Engineering
Building Automation System
Production System
Augmented Reality
Unity Pro/ STEP 7
PLC or embedded devices
Production System
Automation Systems Demonstrator
© Automation Systems Group, WMG, University of Warwick, 2014
Automation Systems ‐ FocusAutomation Systems ‐ Focus
Modelling Deployment SupportModelling eployment Support
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Areas of Training UG PG and R&D ActivitiesAreas of Training, UG, PG and R&D Activities
• Industrial applications engineeringIndustrial applications engineering• Virtual engineering and commissioning• Control systems (PLC, Drives, HMIs)• Web Services, SoA, Cloud Computing, , p g• Migration from legacy to current and future
technologiestechnologies• Collaborative engineering
( l h i )(across supply chain)
© Automation Systems Group, WMG, University of Warwick, 2014
Case Study – Powertrain assembly
o Oil pan rundown o Block load o Trigger wheel assembly o Engine offload o Manifold rundown o Coolant cavity leak testo Coolant cavity leak test o Ball seal and cup plug o Clutch assembly
o RTV oil pan
o Intake tappet selection o Exhaust tappet selection o Tappet verification
o Tappet selectiono Machining cells
(MAG, Marposs, EWAB, Liebherr)
Misc.(MAG, Marposs, EWAB, Liebherr)
© Automation Systems Group, WMG, University of Warwick, 2014
Component based concept and data reuse
CAD control kinematicsata
ng. FBs Software Template
EE
I/Os
+ +
Eng. d
Pre
En
+EN
ENOEN
ENOEN
ENO
+
nts
Re-usable l ibrary
Compone
Mappin
g
C Re-usable l ibrary
M
Step 7
Unity Pro
Syste
m
allation
Re-usable l ibrary Inst
© Automation Systems Group, WMG, University of Warwick, 2014
Lifecycle SupportLifecycle Support
System SimulationAuto‐ Semi‐ or Manual Stations • Cycle time verificationAuto , Semi , or Manual Stations • Cycle time verification
• Process verification• Complexityp y• Clash checks• Energy utilisation
/• MODAPTS/MTM generation• Operator fatigue rating• Ergonomic study• Ergonomic study
© Automation Systems Group, WMG, University of Warwick, 2014
Assembly Automation
© Automation Systems Group, WMG, University of Warwick, 2014
Lifecycle Example
Virtual
Control Logic
MMessages
HMI Information
…
… DeployCapture & Reconfiguref g
Physical (PLC or Distributed Device)
Step 7 for SIEMENSDownload
Unity Pro for SE
© Automation Systems Group, WMG, University of Warwick, 2014
Automation Systems Workbench & DemonstratorAutomation Systems Workbench & Demonstrator
© Automation Systems Group, WMG, University of Warwick, 2014
Automation Systems DemonstratorAutomation Systems Demonstrator
© Automation Systems Group, WMG, University of Warwick, 2014
Cyber Physical Systems
© Automation Systems Group, WMG, University of Warwick, 2014
Design data• 3D CAD• Layout
P• Process• Resource
Facilities / Building
AR Applications for Shop Floor Level:‐ Real time production monitoring
Real time data• Control state• Energy• Production mon.
Manual Operation
Real time production monitoring‐ Direct system data access‐ System design support‐ Enhanced Training‐ Maintenance support
Real time collaboration• Sensing(temp, vib)
Vid f d
‐ Real time collaboration‐ Etc.
History data/logs• Maintenance• Production Log• Training
AutomationCapture/Display devices
Video feed QR/Image recognition
Data feed
Digital/Virtual Environment Real EnvironmentAugmented Reality
de ces
© Automation Systems Group, WMG, University of Warwick, 2014
T d fl t i f ti i f t tTowards a flat information infrastructure
ISA‐95
© Automation Systems Group, WMG, University of Warwick, 2014
SS
Assembly Automation
SS
SS
SS
SS S
SS
© Automation Systems Group, WMG, University of Warwick, 2014
Migration to Cyber Physical Systems and SoAMigration to Cyber Physical Systems and SoAEmergent Behaviours
S iS i
Migration Path 1
Migration Path iService Cloud
Service Cloud
Control / InterlockingControl / Interlocking
Sensor/Actuators
Process
Sensor/Actuators
ProcessMigration Path n
Current Implemented SystemsLegacy
Next GenerationSoA-based System
Source: IMC‐AESOP
© Automation Systems Group, WMG, University of Warwick, 2014
Building Capability:Thoughts to End onThoughts to End on
Collaboration• Tell us your needs – industry-driven teaching, training and R&DTell us your needs industry driven teaching, training and R&D• Use our facilities with us – student projects, training modules, EngD/PhD, R&D• Focused relevant training to address skills shortages• Education at all stages from school through to advanced researchEducation at all stages from school through to advanced research
Opportunities• R&D across the TRLs• R&D across the TRLs• TSB, EU, EPSRC collaboration• Benefit from the latest technologies and methods• Support new supply chains in the UK for new powertrain technologies• Support new supply chains in the UK – for new powertrain technologies
ExamplesAutomation system design and lifecycle support• Automation system design and lifecycle support
• Prototyping new system layouts and production processes• Safety and security implications of new technology, e.g. Internet-based services
© Automation Systems Group, WMG, University of Warwick, 2014
Th k Y !Thank You!Robert Harrison
b t h i @ i k [email protected], Automation Systems Group
© Automation Systems Group, WMG, University of Warwick, 2014