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CRC 1026 Sustainable Manufacturing – Shaping Global Value Creation Funded by German Research Foundation (DFG)
Collaborative Research Centre 1026 Sustainable Manufacturing – Shaping Global Value Creation
MaketechX – 09. November 2013 Dr.-Ing. Jérémy Bonvoisin, Dipl.-Ing. Bernd Muschard
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Resource challenge
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Resource challenge
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Prosperity for everybody?
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Quality of life and consumption of resources
Page 8 Source: [Seliger, 2010]
Early Industrialised countries
Maintaining th
e qu
ality of life while
redu
cing th
e resource con
sump9
on
Improving quality of life with a
responsible consump9on of resources
Emerging countries
Responsible consump9on of resources
Acceptable living standard
Irresponsible development path: Wealth for all people
relying on present technologies
Quality of life
Consum
p;on
of resou
rces
Acceptable living standard with responsible
consump9on of resources
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CubeFactory
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Learning environment to promote sustainable value crea9on in areas with insufficient infrastructure
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CubeFactory
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Recycling
Designing
Manufacturing
Use B6, C5, PA: CubeFactory Learnstrument
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Non-renewable resources ABS: recyclable plastic derived from local waste Local needs
Manufacturing
Renewable resources PLA: biodegradable plastic derived from starch
Manufacturing: Open Source 3D printer as sustainable machine tool to create values and as an instrument for learning
Energy storage: Lithium iron phosphate (LiFePO4) battery with high power density
Energy supply: Off-grid power supply by detachable high-efficient solar panels (200W/m2)
Material supply: Plastic recycler for local available materials to supply 3D printer filament
Knowledge transfer: Intuitive learn and control environment to teach sustainable value creation
Learning environment to promote sustainable value creation in areas of insufficient infrastructure.
u Enables user to create sustainable values u Teaches a closed loop material cycle u Contains all necessary infrastructure for
production u Manufacturing, energy and material supply,
knowledge
Solar power
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DIY -‐ Bicycle
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Population
Living Standards
Environmental Impacts
Time
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Population
Living Standards
Environmental Impacts
Time
Consump;on Pa>erns
Processes Products
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Cra?manship
Autonomous produc;on
Mass produc;on
Mass produc;on
DIY
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Thank you for your aHen9on
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Backup
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u Challenges
u Collaborative Research Centre 1026
u CubeFactory
u DIY - Bicycle
Contents
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Structure of the Collaborative Research Centre (CRC) 1026
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Global value creation
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Source: [Seliger, 2010]
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Increasing the teaching and learning productivity
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Governmental Organisa;ons Big Enterprizes NGOs
Na;ons Unions Industries
Educa;onal Ins;tu;ons Schools SMEs
boHom-‐up approach
Educa;onal Ins;tu;on
Governmental Organisa;ons
Non-‐Gonvernmental Organisa;ons
Enterprizes
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Depth and breadth of CRC 1026
Combining the breadth of systemic reference with the depth of produc9on technology to enable for sustainable value crea9on
Collabora9ve Research Centre 1026
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Meeting the challenge
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Sustainable manufacturing community
I want a product
I design products
I design VCNs
I design workplaces
101011001
1010110011010110101 101100110
1011010
+
+ +
Legend: VCN: Value creation network
Sustainable manufacturing community cloud
I configure VCNs
I run a factory
I do research for the
CRC 1026
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Project Area A: Strategy development
Mul9-‐Criteria System Dynamics Op9misa9on
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Sustainability Indicators
Microeconomic / Macroeconomic Assessments
Technology Pathways
Wide Range of Possible Scenarios
Mathema9cal Models and
Solu9ons
Life Cycle Aspects
Technology Assessment and
Global Consequences
Selected Scenarios as tools for evalua;on
Models
Parameter
Tools
Effects Knowledge flow
A2
A3 & A4
A5 & A6
A1
Research Create Projects
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Project Area B: Production technology solutions
Virtual Product Crea9on
Resource Efficient Produc9on Technologies
Integra9on Shop
Lightweight & Accuracy Improved Machine Tool Structures
Value crea9on networks
Microsystem technology,
adadaptronic enhanced structures
Industrial informa9on technology
Turning, cleaning, welding
Demonstrator
Processes
So?ware tools
Flexible machine tools
Knowledge flow
B1
B2 & B3
B4 & B5
B6
Research Create Projects
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Project Area C: Principles, methods and tools for qualification
Learnstruments, Human Oriented Automa9on
Strategic Interac9on and Incen9ves for Sustainable Economic Ac9vity
Experimental economics and
macroeconomics
Educa9on methods
Quality science, integrated
sustainabilty repor9ng
Strategies for connected economies
Models
Learnstuments for individuals
So?ware-‐tool for sustainable management
C1 & C2
C3
Research Create Projects
C4 & C5
Mul9-‐Perspec9ve Modeling, Intellectual Capital and Knowledge Management
Effects
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C4 Methods for Human Oriented Automation – Approach
u Technology u Markerless Motion capturing in industrial environment u Automatic in-process worker ergonomics analysis using
industrial standard (EAWS)
u Applications u visual guidance for ergonomic
qualification u automated support during physical
work
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C4 Methods for Human Oriented Automation – Results 2012
u Conception of „Human centric workplace“ for worker qualification
u Stereo camera algorithms
u Automatic ergonomics analysis using Microsoft Kinect 3D camera
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C5 Learnstruments in value creation modules – Challenge
Combined Learning and Working Environment
Development and Selection of Learning Methods and Tools
Design and Application of Industrial Artifacts
Learnstrument Development in Design for Mediation Approach
Learning Environment Working Environment
Learner Learning Material Learning Task
Worker Equipment Work Task
User Learnstruments Tasks
u Goal: Increase in Teaching and Learning Productivity for Sustainable Manufacturing through application of Learnstruments
u Approach: Learning and user centered design in combined learning and working environment
User Centered Tool Development Competence
Portfolio
Learning Centered Task Development Learning Cycle
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C5 Learnstruments in value creation modules – Approach
Learnstruments are objects which automa;cally demonstrate their func;onality to the learner. They consist of aspects of cogni&ve s&mula&on and emo&onal associa&on with new and exis;ng ICT and design approaches for produc&ve media&on.
Adapta9on of func;onality and interfaces
Combina9on with learning
materials program
Technology iden9fica9on
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C5 Learnstruments in value creation modules – Results 2012
User Centered Tool Development Competence Portfolio
Portfolio Strategy: Increase error tolerance for untrained and unqualified users
Learning Centered Task Development Learning Cycle
Cycle Strategy Learnstruments cover all aspects of the perception and processing continua for highest teaching productivity
Processing Continuum Pe
rcep
tion
Con
tinuu
m
Innovation and Transformation,
Active „experímenting“
Skills, Active Experimentation
„Doing“
Systemic Knowledge, Abstract
Conceptualisation, „Thinking“
Awareness, Reflective
Observation, „Watching“
Motivation, Concrete
Experience, „Feeling“
Kno
wle
dge
Skills
qualified
untrained
unqualified
qualified
trained
unqualified
trained untrained
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Population
Time
Use productivity of resources
Living Standards
Population
Resource Consumption
Resources Consumption
Living Standard
Ecologic Constraints
Population
Living Standards
Living Standards
Resources Consumption Time
Social challenge of use productivity of resources
Source: [Seliger, 2005]
Limit popula;on growth by increasing living standards
Higher living standards conflict with ecological limits due to an increased consump;on of resources
An increase of the use-‐produc;vity will allow for the desired increase of the living standards within the planets ecological limits
Higher living standards are sustainable only when the per capita resources consump;on decreases
Time
Time
Ecologic Constraints
Time
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Challenge of resource efficiency and energy conversion
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u Keeping non-renewables in product and material life cycles without disposal
u Substituting non-renewables by renewables
u Consuming renewables only to the extent that they can be regained
100% global annual primary energy resources correspond to about 500 EJ [Exajoule = 1018 Joule] or 140 PWh [Petawatt hours = 1015 Watt hours]
Source: [VDI, 2010; Cullen, 2010; Seliger, 2010]
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Environmental challenge of consumption of renewable resources
Population [Mio.]
Ecological Footprint
[global ha/cap]
Biological Capacity
[global ha/cap]
Ecological Deficit (-) or Reserve (+) [global ha/
cap]
World 7.112 2.4 1.8 -0,9
Brazil 198.4 2.9 9.6 +6.7
China 1.353.6 2.1 0.9 -1,2
Germany 82.0 4.6 2.0 -2,6
India 1.258.4 0.9 0.5 -0,4
Japan 126.4 4.2 0.6 -3,6
Russia 142.8 4.4 6.6 +2.2
USA 315.8 7.2 9.6 - 3.3
u 12,8 billion ha divided by 7.112 billion people: The planet‘s bio-capacity is 1.8 global ha/cap.
u Global bio-capacity of 1,8 global ha/cap equals an ecological deficit of 50 % or 1.5 earths.
Source: [WWF 2012; World Bank, 2013]
1961
Global Ecological Footprint
Eco
logi
cal F
ootp
rint (
Num
ber o
f Ear
ths)
CO2 Share of the Global Ecological Footprint
0
2
1970 1980 1990 2000 2008
Biological Capacity
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A1 Pathways for sustainable technology development – Challenge
u Challenge u Different requirements for different development levels u Rapid technology development u Lack of orientation in knowledge landscape u Limited interdisciplinary knowledge
u Goal u Robust technology pathways for different
levels of development u Exploit technological potentials for
useful applications u Connect technological concepts
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A1 Pathways for sustainable technology development – Approach
Systems
System elements
Mobility Energy Production
Functions
Specific Criteria
General Criteria
Substitution Combination
System creation
Technology pool Surrounding field scenarios
Assessment
or
Functions
Syst
ems
Con
ditio
ns
System elements
Syst
em
elem
ents
Area of human living
Sustainability dimension
Development level
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A1 Pathways for sustainable technology development – Results 2012
u Surrounding field scenarios u Energy scenarios for developing countries u Production scenarios for developing countries u Mobility scenarios for emerging and
industrialised countries u Public transportation in Sao Paulo u Bicycle mobility in Berlin
u Three pathways identified u Technology oriented
u with existing system implemented in LEG2O machine tool
u with system element implemented in hydrogen based mobility
u Problem oriented implemented in decentralised energy supply in developing countries and cocoa mass production in developing countries
Mobility Scenarios 2030
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A2 Sustainability Indicator Development – Challenge
u Integration of the three dimension of sustainability u social, environmental, &
economic
u Creation of indicators for the manufacturing community u usable at a brought field
of different applications
Sustainable indicators
Manufacturing network
Knowledge & stakeholder
Porous knowledge
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A6 System Dynamics Optimization – Approach
u Core Product: Software package „System Dynamics SCIP“
u Branch-and-bound approach to control problems: u Division of the problem
into subproblems u Solution of linearized
subproblems using Simplex Method
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B1 Virtual product creation in sustainable value creation networks – Challenge u Engineering Challenges
u An engineer must consider each lifecycle phase when designing a product
u He / she must be supported with information related to the sustainability of the product
u An approach is necessary defining u when (process)
u how (methods) and
u by which information (decision support)
the engineer can be supported in designing sustainable products
Product Design Alternatives
Optimised Product Design
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B1 Virtual product creation in sustainable value creation networks – Approach u Development Process
u Analyse, modify and complement development process for creating sustainable products
u Methodology u Analyse, combine and, if needed, modify
methods for sustainable product development
u Decision Support u Identify and combine information/knowledge u Develop ontology for combining information u Implement Methodology database u Decision assistant (software)
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B1 Virtual product creation in sustainable value creation networks – Results 2012
u Methodology (Database) u Collection of Methods
(110, appr. 50 sustainability related)
u Classification of Methods
u Overview on database Options
u First approach for defining goals for combining methods
u Process u Interview partner in
industry identified to analyse Product Development Processes (PDP) and discover potentials
u Collection of public PDPs
u Decision Support u First terminology as a
basis for the ontology
u Analysis of ontology tools
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B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Challenge
u Motivation u Development of an innovative concept for machine tool frames capable of adapting to
continuously varying production tasks, - requirements and - locations u Provision of advanced functionalities of the single modules, e.g. identification, communication
and distributed sensing as key requirements for hardware concept u Challenge
u Fusion of microsystem technology (MST) based systems with machine tool (MT) components u Alignment of use times of MST and MT components considering effects of aging, failure and
innovation cycles u Sustainability aspect
u Reconfigurable machine tool structures, allowing for a more intensive, effective use of equipment u Flexibility and mobility of production systems through moderate module sizes u Exchange, upgrade or repair depending on technical condition and market demands u Implementation of EcoDesign strategies for electronics development
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B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Approach u Concept
u Replacement of conventional monolithic frames by lightweight, accuracy optimized and reusable frame modules
u Active and passive modules to compensate thermally and mechanically induced or structural deformations
u Microsystem technologies to provide enhanced functionalities
u Value creation u Flexibility with respect to application
scenario u Cost reduction along with environmental
improvements through more intensive and/or prolonged use times of equipment
u New perspectives with respect to mobility, scalability and mutability of production systems
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B4 Development of microsystem enhanced machine tool structures for lightweight and accuracy optimized (LEG²O) frames – Results 2012
0.00
µm 2.29 1.15
5.17 (a)
u Machine tool concept u Modules must be easy to manufacture and
guarantee a repeatable and easy assembly u Low module weight ! transportability u Thermal, static and dynamic properties
similar to monolithic frame properties u Side length of 200.0 mm and plate thickness
of 10.0 mm u Honeycomb structure is favorable design
(c)
7.26
0.00
µm 3.23 1.61
(b)
4.88
0.00
µm 2.17 1.09 Deflection simulation results (a) regular cube,
(b) lightweight cube (c) honeycomb
Regular cube
Light-weight cube
Hexagon-comb
Weight - 22.5 kg
+ 19.5 kg
++ 18.8 kg
Welding - + -
Machinability + ++ -
Stiffness + - ++
Fill damping material
+ - +
Table to assess design concepts
u Microsystem technology concept u Prototypical sensor system setup for first
evaluation of measurement concepts and energy saving potentials
u Provision of data from distributed sensor nodes via central PC, using webserver as interface for MST/MT
u Investigation of environmental impacts of wireless sensors using indicators for toxicity and resource scarcity
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