Industry 4.0: digital technology in microtechnology › ZOOM_2018_EN.pdf · - a laser marking...
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1/8 Zoom 2018
ZOOM 2018
Industry 4.0: digital technology in microtechnology An autonomous production unit in operation
In 2011, fearful of being dethroned by competition from GAFA, German industry leaders
launched the 4th industrial and social revolution based on a digital transformation of the
industrial model called “Industry 4.0”.
With the advent of digitisation, industry is becoming an interconnected global system in which
machines, systems (ERP) and products communicate non-stop.
Industry 4.0 consists of connecting the Internet of Things and the Internet of Services. The
goal is to increase productivity with zero defects guaranteed, to produce small series within
the same times and costs as mass production series.
With this approach, as soon as an order is accepted, the entire supply chain process is set in
motion. ALL participants and departments from design to production must be interconnected
and work consistently and effectively, thus drastically reducing time lags between the various
technical operations.
The 2018 Zoom event will show that this revolution, which is having a big impact on large
groups, should not be restricted to these groups, but should also impact the industrial fabric
of SMEs and even SOHOs.
This is why Micronora wanted to present an autonomous production unit in operation
including:
- a design station
- a machining station
- a control station
- a 3D manufacturing station
- an assembly station with a collaborative robot
- a laser marking station
The stations are connected by an automated guided vehicle (AGV) equipped with a robotic
arm, saving time between each station.
The supervisory software controlling the AGV ensures the connection between the Internet
of Things, and in part, with the Internet of Services.
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2/8 Zoom 2018
The operations take place as follows:
Creation of an original object combining two technologies (machining and 3D printing).
- AJ Solutions (SOLIDWORKS environment) designs the 3D object on a computer and
sends the file to the Willemin-Macodel 701S high-precision machining centre.
- The created object is placed by a machine-integrated robot onto a tray that is given to
Stäubli’s HelMo AGV, which is the real backbone of the APU, transferring the objects
without any time lags. This mobile robot sets the pace for the entire production,
transporting objects from one station to another.
- The quality of machining is controlled by Alicona's advanced InfiniteFocusG5 surface
metrology system.
- The object’s 3D file has also been sent to Frenchmakers’ 3D printers, which create the
resin objects.
- A QR code is laser engraved by IMI Group subsidiary Laser Cheval’s LEM Quartz on the
machined object to download all the information about the equipment presented.
- The two parts (machined object and resin object) are assembled by ABB’s collaborative
robot YuMi, an icon of Industry 4.0.
- The finished object is then given to the visitor.
- With the AGV, the object is created in just 10 minutes thanks to extensive engineering
work by MC Robotics and its Kactus software.
This flexible, highly digitised and automated production unit
can be adapted to different industrial processes
without any major investment
and without extensive changes to the system in place.
Through this event,
Micronora wants to encourage SMEs and SOHOs
to modernize their production equipment
and help them to join the industry of the future.
Video: https://www.youtube.com/watch?v=3MrT_c5jDtE
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3/8 Zoom 2018
Zoom 2018: APU, who does what?
AJ Solutions: design/manufacturing and manufacturing simulation software
From preliminary design to manufacturing simulation via
product development, AJ Solutions is the first building
block of the APU. “The SolidWorks tools used will cut the
product development cycle by optimising the different
design stages”, explains Thomas Castalan, business
engineer at AJ Solutions. “At the Zoom, we will create a
typical design providing solutions to the problems of today
and tomorrow's manufacturers”. Distributor and
authorised training centre for the SolidWorks
environment, AJ Solutions helps the users of its services to
optimise the product development process. With new features in 2018, including innovative
topological study solutions integrated into SolidWorks Simulation Professional 2018,
companies optimise their parts to obtain the minimum weight for a given amount of rigidity.
The new Manage tool provides a powerful solution for project management. SolidWorks
Composer enables you to quickly create product animations and graphics from existing 3D
models with assembly instructions, printed marketing brochures, technical illustrations,
interactive animations or training materials.
Willemin Macodel: machining
The 701S machining centre designed by Willemin-
Macodel’s engineers will provide fast and ultra-precise
part machining at the Zoom. “This 3-axis machine with
parallel kinematics is part of a flexible manufacturing
line, computer-managed in real time”, says Bertrand
Decloux, head of sales in France at Willemin-Macodel.
“It enables fully-automated production of various types
of objects and in varying quantities. Its tool and parts
magazine solves planning and scheduling problems”.
The 701s machine is the first machining centre to make
use of the dynamics and rigidity of Delta-type
kinematics. Packed with innovation, the machine offers
the technical features essential for micromachining
applications. The ultra-high-performance powered
spindle was created specifically for harmonised use with
the kinematics of the 701S machine. The tools are
attached directly onto the powered spindle without a tool holder. Its maximum rotation speed
is 80,000 rpm.
www.ajsolutions.fr
www.willemin-macodel.com
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4/8 Zoom 2018
Stäubli: the mobile robot system
Setting the pace, the HelMo robot developed by
Stäubli will physically connect the different
workstations of the Zoom APU. To do so, it will
communicate with each apparatus on the
production line. This innovative system can move
and navigate autonomously. It monitors its
environment continuously using three integrated
laser scanners. This robotic system can perform
fully-automated tasks at a high speed or, if
necessary, work alongside human operators.
HelMo’s design is based on a standard TX2 robot.
The six-axis TX2touch 90L has a maximum load
capacity of 15 kg and a range of 1,200 mm. This
cutting-edge solution enables direct human-robot
cooperation. To meet stringent technical safety requirements, Stäubli’s system has a complex
safety package and a CS9 safety control system. Another distinguishing feature of this robot is
the Safety-Skin, a surface protection system that is touch-sensitive and stops movement
immediately in the event of direct contact with a person. All safety features are certified and
meet the strict requirements of safety category SIL3-/PLe. “The mobile robot system is
modular and has an automatic toolchange system”, explains Jacques Dupenloup, sales
manager for France and Benelux at Stäubli. “That allows HelMo to be used for a wide range of
purposes, enabling it to take on tedious tasks for staff. It can be seen more as an assistant who
is always there when you need it. This is an illustration of the evolution of industrial robotics,
which will become ever more mobile”.
Alicona: control-measurement
At the APU’s quality control station for Zoom 2018, Alicona will
showcase its most advanced surface metrology system,
InfiniteFocusG5. Thanks to its focus variation technology, it can
measure roughness and shape with the same system. The
range of measurable surfaces and materials is practically
infinite thanks to dual coaxial and annular LED lighting. The
user achieves high resolution measurements and connectable
and repeatable results. All surface characteristics are
measured using a single multifunctional sensor. The optimum
measurement parameters can be set entirely automatically.
Multi-user and multi-setting use for different materials and applications is easy to set up. “The
speed of the measurement combined with the absence of contact with the workpiece and the
possibility of measuring on steep inclines are valuable advantages for production inspections
on machined parts”, explains Anne Calvez, manager of Alicona France. “Our systems can be
used on the production line or integrated into a machine tool to be interfaced in an 4.0
industrial process”.
www.alicona.fr
www.man-and-machine.staubli.com/helmo/
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5/8 Zoom 2018
FrenchMakers: 3D printing
Zoom 2018 will exhibit a continuous part production system
using FDM (fused deposition modelling) integrated into an
automated assembly to form an autonomous manufacturing
unit. The parts produced are temporarily stored and the
software that supervises the APU is notified when they are
available. The software then ensures that they are collected
and sent to an assembly robot. “Additive manufacturing is
increasingly popular and offers companies not only a rapid
prototyping method, but increasingly, a production capacity
for parts”, explains Vincent Rousset, director of FabLab in
Besançon. Customizable, these parts can be produced in small
and medium series. FrenchMakers sells all products and materials for 3D printing, provides
training and maintenance, and manufactures prototypes under subcontracts. Through its
expertise in software tools and additive manufacturing equipment, the Besançon company
has developed its own tools to meet the needs of its customers: specific 3D printers,
management of 3D printer farms, automation of everyday tasks, etc. It creates a complete
digital manufacturing ecosystem for professional and corporate “makers”.
Laser Cheval: laser engraving
The subsidiary of the IMI group will contribute to the Zoom APU with
the LEM Quartz laser marking machine, which will laser mark a
Datamatrix code on the machined part deposited on the work tray by
a robotic arm. The LEM Quartz is a precision micro-machining
machine with an automatic door. “It can integrate all the laser
marking systems in our range, from 150 picoseconds (short pulses) to
200 nanoseconds”, explains Dominique Cilia, director of Laser Cheval.
“With this type of source, the engraving and micro-machining quality
is improved: the finish is flash-free on brass and there is almost no
oxidation on stainless steel”.
With a floor space requirement of just over 0.5 m2, this equipment is
packed with features. It has a granite bench for stability, a work tray
measuring 400 X 600 x 50 mm, and a 5-axis system (3 mechanical axes
and 2 optical axes for the laser beam). This enables greater precision
when moving parts and an automatic visual resetting system to
optimally position the laser beam on workpieces.
With this latest-generation technology, users have an efficient multifunctional tool. Virtually
all applications are possible on all metal materials and many plastics, composites and
ceramics. A wide range of operations are accessible: all types of marking for decorative
purposes, identification (barcode, Datamatrix, etc.) and referencing purposes, but also 2D or
3D machining, replacing traditional mechanical or chemical methods. The machine is
extremely easy to use (no specific tools, easy programming) and has an intuitive
human/machine interface.
www.lasercheval.fr
www.frenchmakers.com
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6/8 Zoom 2018
ABB: robotic assembly
A pioneer in collaborative robotics, ABB will present its
YuMi (You and Me) two-armed robot at the Zoom event.
“Able to work safely side-by-side with humans on the
same tasks, YuMi can handle any object with such
precision that it can thread a needle”, says Guillaume
Pradels, head of collaborative robots at ABB France. “It
meets the new needs of users assembling small parts,
with higher production volumes and shorter product life
cycles and production times, and the growing product
customisation trend (especially in electronics)”. This
two-armed collaborative robot has flexible hands, a universal part feeding system, integrated
vision and state-of-the-art trajectory management. During the Zoom it will assemble the metal
and plastic parts of the object to be manufactured by the APU.
MC Robotics: APU engineering and supervision
This Besançon startup engineered and supervised the APU. “MC
Robotics will present its new robotic software solutions at this
mini production plant”, says Mathieu Charles, president of the
company. “The major advantage of Industry 4.0 is that you can
retrieve production data to use it more efficiently. In an era of
collaboration between humans and machines, we believe that
to collaborate more efficiently, the machine must adapt to the
human”. MC Robotics develops industrial user interfaces as
practical and fun as a smartphone interface. “This production
line was entirely integrated and simulated on our Kactus
software to confirm its feasibility”, the specialist adds. “That
means you will be able to observe several different brands of
equipment working in perfect harmony. They communicate,
exchange data and question each other without the operator realizing the amount of
information being exchanged. Today, what is more difficult than getting several different
brands of machine to communicate with each other? The time needed to develop an industrial
solution of this type must essentially be spent on developing the process rather than on
establishing communication between the different elements”.
www.mcrobotics.com
http://new.abb.com
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7/8 Zoom 2018
ZOOM ORGANISATION
On the central island
- Autonomous Production Unit (APU)
In the surrounding area
Predictive maintenance
Femto-ST Research Institute
Today's industrial equipment has sensors creating a massive
flow of data that is difficult to fully leverage. One of the major
challenges for factories in the future will be to give meaning
to all this information.
The Prognostic and Health Management team at the Femto
ST Research Institute is developing innovative approaches for
predictive maintenance based on mathematical tools and
artificial intelligence technology. These research projects are
perfect examples of the Industry 4.0 concept.
Robdec - Cutting workshop robotization
Cetim / Process Industrie / MC Robotics / S.mart / PerfoEST
Goals
To propose a robotic cell for loading/unloading reworking
presses
Mobile, flexible and a rapid return on
investimentguaranteeing operator safety
Solutions
- A modular "architecture" with 1 or 2 robots
to adapt to cycle time requirements
- An architecture including sub-assemblies
that can be easily moved and quickly adapted
to the different machines in the workshop
- A flexible part feeding system using a conveyor,
vision sensor and LED lighting
- Safety partially achieved by a dual zone laser scanner
avoiding the need for guarding
around the robot
- Interface with the presses without changing the control or its safety features
- A programming tool separate from the robot and based on a Grafcet-type model
to facilitate programming by operator-setters
www.femto-st.fr
www.cetim.fr
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8/8 Zoom 2018
Aeroμtech cluster
A major industrial sector at the forefront of the 4.0 industrial revolution
The Burgundy Franche-Comté aerospace and defence cluster, launched a little over a year ago,
already has more than thirty members. Having become a leading force, these companies, will
be first-time exhibitors at the Zoom in 2018 under the name Aeroμtech.
“The aim of this cluster is to foster the right conditions for successful innovation projects, the
development of sales activities, the creation of new companies in the region and the
international visibility of local operators”, enthuses Thierry Bisiaux, president of both the
Cluster and the Cryla Group, and a fervent supporter of this thriving partnership. “It is all about
being included in a fertile network of companies that are recognised internationally for their
expertise”.
The cluster is an organisation managed by a steering committee and supported by thematic
working groups led by member companies. “This helps to endorse innovation projects in these
areas, find funding and build strong ties between companies, research laboratories and
training organisations”, says Malua de Carvalho, general representative of Aeroμtech. The
ability to meet all the needs from A to Z of prime contractors in aerospace and defence is the
key asset of these subcontractors, who have purposefully tailored their equipment and
organisation.
A member of GIFAS
Fully immersed in the French aerospace industry, the member companies have greater
visibility of the supply chain.
The cluster is the region’s preferred partner for the creation and management of major
programmes in the sector, such as the Industrial Performance Programme, whose project
manager is France’s aerospace industry association, GIFAS. Regional companies therefore
benefit from the financial support of the region and the industry to participate in a
programme. The aim of the programme is to help them achieve the industrial excellence
needed to meet the challenges of the growing production of civil aircrafts that comes with the
sharp increase in air traffic expected over the coming years.
Supported by Zodiac Aerospace
Involved in the working groups, the members attend networking meetings, market
information days, trade fairs, international missions and conferences organised by the cluster
with the strong support of Zodiac Aerospace - Besançon, by way of Cyril Magnin, production
manager and vice-president of the cluster.
The Micronora trade fair is an excellent opportunity to showcase the dynamics and expertise
of Burgundy Franche-Comté companies on the aerospace market.
Conference
Aeroμtech will organise a conference on 26 September, during which it will present the
challenges of the future aerospace industry and the progress of the Industrial Performance
Programme, in the presence of representatives of the GIFAS Aero SME committee.
www.aeromicrotech.com