Smart Factory - AgoriaMar 03, 2015 · 3/3/2015 11 setup Machine Mazak Integrex 200-IV multi-task...

3/3/2015

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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


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

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Automated quality control for small series


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

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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] |

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CMM program


CMM program



CMM program

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CMM program

Tool compensation



CMM program

Tool compensation

CMM outputfile

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Automated quality control small series


CMM program

Tool compensation

CMM output file GUI w Operator input



CMM program

Tool compensation


ISO CNC file

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CMM program

Tool compensation


ISO CNC file Call ISO subroutine

Toolcompensation


CMM program

Tool compensation

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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

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Process control for small series

“Signature analysis” applied to a CNC machine


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

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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

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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

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3-3-2015 26 © Sirris | www.sirris.be | [email protected] |

https://www.youtube.com/watch?v=x4a4n8n5p5E

https://www.youtube.com/watch?v=x4a4n8n5p5E

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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

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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


Production

engineering

Gripper design

Universal local

storage

Robot

programming

Production

Process

monitoring

Tool monitoring

Control

Quality control

+32 498 919485

[email protected]

Jan Kempeneers

3.03.15 © sirris | www.sirris.be | [email protected] |

be.linkedin.com/pub/jan-kempeneers/20/12b/38/

@JanKempeneers

3/3/2015

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http://www.sirris.be

#sirris

http://www.linkedin.com/company/sirris

3.03.15

http://techniline.sirris.be

© sirris | www.sirris.be | [email protected] |

Smart Factory - AgoriaMar 03, 2015 · 3/3/2015 11 setup Machine Mazak Integrex 200-IV multi-task...

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