Paul Warndorf Vice President - Technology

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Paul WarndorfVice President - Technology

Smart MachineSmart MachinePlatform InitiativePlatform Initiative

NDIA Manufacturing Division MeetingMarch 8-9, 2006

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Smart MachinePlatform Initiative

$2 Million Awardthrough

Department of Defensefor

FY2006

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SMPI Program

• 3-4 year effort• $2 million for year one• Development efforts will be limited and need

to show early success• Plan to link with other funding programs to

cooperatively achieve end goals• Believe there is opportunity to provide a basis

for future innovative developments

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Program Management

Funding Source– U.S. Army Research Laboratory,

Aberdeen Proving Grounds, MD

Program Office– Benét Laboratories, Watervliet,

NY

Program Manager – TechSolve Inc., Cincinnati, OH

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2000First Product Correct

2002Smart Machine Tool Workshop

1996AMT Technology Roadmap

SMPI History

2003-2004Smart Machine Tool Agenda

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Coalition on Manufacturing Technology Infrastructure

• AMT• IMTI• NCMS• NCDMM• NACFAM• NTMA• SME• TechSolve

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Mission

To identify, develop, and initiate programs to support the

revitalization of the technical infrastructure for the nation’s

small, medium, and large manufacturing industries

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First Product Correct

AssemblyPart

Product

AssemblyPart

Product

First Part CorrectCapable Processes

Self-FormingEnterprises


First ProductCorrect


Intelligent, Adaptable

Equipment & Processes



ProductRequirements

ProductRequirements

Product & ProcessDefinitions


Product & ProcessDescriptions


TransparentExchange ofInformation


Modeling/SimulationDecisions for

Total Manufacturing


Total Manufacturing Self-Maintaining &Self-Monitoring Systems

Self-Maintaining &Self-Monitoring Systems

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Smart Machine Platform Initiative (SMPI)

- General Concept -Assembly

PartProduct

AssemblyPart

Product










ProductRequirements

ProductRequirements








Total Manufacturing




AssemblyPart

Product

AssemblyPart

Product











ProductRequirements

ProductRequirements








Total Manufacturing




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AMT – Global TechnologyAdvisory Board

• Caterpillar• Boeing• GM• P&W• Timken• Alcoa• U.S. Army• NCMS• NAMRI

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GTAB Mission

To provide guidance on technology needs and trends to the membership of AMT

so they can develop and deploy leading and competitive products.

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Process Capability

PAST FOCUS CURRENT TREND FUTURE TREND

Measurement in months and years

Measurement in minutes, hours, and days

Measurement in real time and ability to forecast process capability and repeatability in real time

Implications

Emulation and validation of processes and operations

o Need for geometric and performance characteristic representation of machine tool design

Higher reliability and predictability of processes

o Need to incorporate more robust sensor feedback

o Increased collection of data and its conversion into meaningful information and its dissemination

o Reliability for next part production

Increased responsiveness of the supply chain (supply chain management)

o Decrease in machine tool delivery lead times

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Optimization

PAST FOCUS CURRENT TREND FUTURE TREND

Process optimization Concentration on specific (point) processes

Product optimization Emphasis on the total process of a product considering all process steps

Integrated product and process design and optimization

Implications

Process capability enables product design Process flexibility to permit variability of products and design

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Knowledge

Processing Data• Process• Tooling• Inspection• Fixture

Local Knowledge • Health• Accuracy• Dynamic Information• Tooling & Fixturing



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Example(Stability Lobes)

Process Planning

Equipment

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Equipment-Based Localized Activities

Global Focused Activities

Equipment

SMPI OperatingSystem

• Health• Accuracy• Tolerance• Dynamic Information• Local Knowledge Base• Tooling & Fixturing

CNC

INPUT/OUTPUT

Process Planning• Global Knowledge• Models• Programming

Other Activities• Tool Management• Maintenance• Inspection & Certification• Fixturing• . . . .

Smart Machine Platform Initiative (SMPI)

- Achieving First Part Correct -

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Year One Deliverables1st Year• Architecture of Global and Local systems and initial

SMPI Operating System• Installed Test-Bed at TechSolve and Benét Laboratory• Initiation of three (3) technology developments• Kick-Off meeting and one (1) status meeting• Identification of technologies that could be provided by

small and medium enterprises to meet SMPI goals• Identification of manufacturing related University

research in technologies appropriate for SMPI• Re-evaluation of the initial SMPI Plan • Assemble an Active Industrial Advisory Group

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Smart Machine Tool Advisory Group(Government)

• U.S. Army Benét Laboratories

• U.S. Army Research Laboratory

• Defense Logistics Agency• Department of Energy, Oak

Ridge Y-12• NIST

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• GE Transportation Aircraft Engines

• BAE• Sikorsky Aircraft Corporation• Caterpillar, Inc.• Lockheed Martin• Delphi• Remmele-Contract

Manufacturing

Smart Machine Tool Advisory Group(Industry)

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Smart Machine Tool Advisory Group(Technology Providers)

• Ex One Company• MAG Industrial Automation

Systems• ?• ?

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Smart Machine Tool Advisory Group

(Commitment)

• Attend general planning and review meetings• Participate in the selection of programs for

funding• Review other funded programs for

applicability to SMPI• Provide nonproprietary information if

applicable

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Smart Machine Tool Advisory Group(Meetings)

• Three meetings have occurred– NCMS, Ann Arbor, MI– Sikorsky Aircraft Corp., Stratford, CT– Defense Manufacturing Conference,

Orlando, FL

• Advisory Group cooperative charter in development

• Next meeting – April 26, 2006

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SMPI Program

IQL

Third Wave

Maintenance

Metrology

Contro

l

Modeling &

Monitoring

Proce

ss

Definit

ion

•CAD/C

AM

•Opti

mizatio

n

•Pro

gram

ming

•Pro

ducib

ility

SMPIDisruptiveTechnologies

MaterialsSensorsDesignNanotech.

? ?

?

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IQL Program(Machine Error Assessment)

FULL VOLUME ERROR MODELX Y Z

Start -289.0000 0.0000 -55.6700End 0.0000 161.0000 0.0000

Travel 289.0000 161.0000 55.6700

Error Description Error Comments Ang Error Offset Full ErrorDir (AS) (in/ft) (in) (in)

1 eXx Lin Acc x Systematic Deviation (E) 0.0016002 erXx Repeat x Unidirectional Repeatability (R) 0.0002003 eYx Str Y y 0.0023004 eZx Str Z z 0.0021005 eAx Roll z Offset Y Travel 8.0 0.00047 90 0.0034926 eBx Pitch x Offset Z Travel+ W Travel - Tool Length 4.8 0.00028 90 0.0020957 eCx Yaw x Offset Y Travel 4.1 0.00024 31 0.0006168 eoCxy Sq x Offset Y Travel 6.0 0.00035 90 0.0026259 eYy Lin Acc y Systematic Deviation (E) 0.003200

10 erYy Repeat y Unidirectional Repeatability (R) 0.00010011 eXy Str X x 0.00030012 eZy Str Z z 0.00040013 eBy Roll x Offset Z Travel+ W Travel - Tool Length 12.4 0.00072 31 0.00186414 eAy Pitch y Offset Z Travel+ W Travel - Tool Length 8.1 0.00047 10 0.00039315 eCy Yaw y Offset Scale Distance from S C/L 10.6 0.00062 10 0.00051416 eoAyz Sq y Offset Z Travel - Tool Length -55.0 -0.00320 90 -0.02400017 eZz Lin Acc z Systematic Deviation (E) 0.00060018 eZz Repeat z Unidirectional Repeatability (R) 0.00010019 eYz Str Y y 0.00010020 eXz Str X x 0.00040021 eCz Roll x No Offset 2.3 0.00013 90 0.00100422 eBz Pitch x Offset Z Travel - Tool Length 2.5 0.00015 31 0.00037623 eAz Yaw y Offset Z Travel - Tool Length 1.6 0.00009 31 0.00024124 eoBxz Sq x Offset Z Travel - Tool Length 4.6 0.00027 31 0.00069825 eXs Rad Err X x 0.00010026 eYs Rad Err Y y 0.00009327 eZs Axial Err Z z 0.00011028 eoAxs Sq SX x or z Offset Tool Length 4.3 0.00025 8 0.00016729 eoBys Sq SY y or z Offset Tool Length 5.3 0.00031 8 0.000207

Sum = 0.005514

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IQL Program(Part Feature Assessment)

Length

Width

HeightSize

Diameter

Straightness

Flatness

Circularity

For Individual Features

Form

Cylindricity

Of a LineFor Individual or Related Features Profile

Of a Surface

Position

ConcentricityLocation

Symmetry

Angularity

PerpendicularityOrientation

Parallelism

Circular

For Related Features

RunoutTotal

Length

Width

HeightSize

Diameter

Straightness

Flatness

Circularity

For Individual Features

Form

Cylindricity

Of a LineFor Individual or Related Features Profile

Of a Surface

Position

ConcentricityLocation

Symmetry

Angularity

PerpendicularityOrientation

Parallelism

Circular

For Related Features

RunoutTotal

FEATURE TOLERANCE RATIOS

Draw ing# Loc. Individual Features Related Features Both Dist. Axes FTR

Size Form Location Orientation Runout Profile X Y Z B # 1 Axis 2 Axes 3 Axes 4 Axes

Part 1/A5 0.150 390 2 0.0004

12345-1 1/A5 0.500 260 3 0.0019

3/D3 0.500 350 4 0.0014

3/D6 0.050 108 2 0.0005

1/B7 0.800 47 2 0.0170

1/B7 0.200 604 2 0.0003

Part 1/B4 0.150 390 2 0.0004

12345-2 2/B6 0.500 260 3 0.0019

2/B3 0.500 350 4 0.0014

6/F2 0.050 108 2 0.0005

6/F2 0.200 604 3 0.0003

6/F2 1.200 193 4 0.0062

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IQL Program(Process Error Budget)

FLAT SURFACE MILLED WITH 12 INCH DIAMETER SHELL MILLPART AXIS MOTIONS

X Y ZStart -180.000 -75.000 -29.000End -60.000 -15.000 -29.000

Range 120.000 60.000 0.000

Error Description Error Comments Ang Error Offset Full Error Adj Error ErrorDir (AS) (in/ft) (in) (in) (in) %

1 eXx Lin Acc x No positioning in X - no error2 erXx Repeat x No positioning in X - no error3 eYx Str Y y Y direction - no error4 eZx Str Z z 0.00210 0.00087 40.9%5 eAx Roll z Offset Part Width (Y Travel) 8.0 0.00047 60 0.00233 0.00097 50.3%6 eBx Pitch x Offset Tool Radius 4.8 0.00028 6 0.00014 0.00006 0.2%7 eCx Yaw x X or Y directions - no error8 eoCxy Sq x X direction - no error9 eYy Lin Acc y Y direction - no error

10 erYy Repeat y Y direction - no error11 eXy Str X x X direction - no error12 eZy Str Z z 0.00040 0.00015 1.2%13 eBy Roll z Offset Tool Radius 12.4 0.00072 6 0.00036 0.00013 1.0%14 eAy Pitch y X or Y directions - no error15 eCy Yaw y Offset Tool Radius 10.6 0.00062 6 0.00031 0.00011 0.7%16 eoAyz Sq y Offset Tool Radius -5.5 -0.00032 6 -0.00016 0.00016 1.4%17 eZz Lin Acc z No change in position - no error18 eZz Repeat z No change in position - no error19 eYz Str Y y Y direction - no error20 eXz Str X x X direction - no error21 eCz Roll x X or Y directions - no error22 eBz Pitch x Offset Tool Radius 2.5 0.00015 6 0.00007 0.00000 0.0%23 eAz Yaw y Offset Tool Radius 1.6 0.00009 6 0.00005 0.00000 0.0%24 eoBxz Sq x Offset Tool Radius 4.6 0.00027 6 0.00014 0.00014 1.0%25 eXs Rad Err X x X direction - no error26 eYs Rad Err Y y Y direction - no error27 eZs Axial Err Z z 0.00015 0.00015 1.2%28 eoAxs Sq SX x or z Offset Tool Radius 4.3 0.00025 6 0.00013 0.00013 0.8%29 eoBys Sq SY y or z Offset Tool Radius 5.3 0.00031 6 0.00016 0.00016 1.3%

Sum = 0.00616 0.00302 100.0%

Part Flatness Tolerance = 0.006 Part Flatness Est = 0.0014 Part Tolerance Ratio = 4.4

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Third Wave Program

Modeling

Simulation

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Next Steps

• Contract Award – Currently stated to be in the April timeframe

• SMPI program first meeting – Currently planned to occur at TechSolve in Cincinnati, Ohio in the May timeframe

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Next Step

Maintenance

Metrology

Contro

l

Modeling &

Monitoring

Proce

ss

Definit

ion

•CAD/C

AM

•Opti

mizatio

n

•Pro

gram

ming

•Pro

ducib

ility

SMPIDisruptiveTechnologies


? ?

?

Maintenance

Maintenance

MetrologyMetrology

Contro

l

Contro

l

Modeling &

Monitoring

Modeling &

Monitoring

Proce

ss

Definit

ion

•CAD/C

AM

•Opti

mizatio

n

•Pro

gram

ming

•Pro

ducib

ility

SMPIDisruptiveTechnologiesDisruptiveTechnologies


? ?

?

• Hold program kickoff meeting at TechSolve in the May timeframe

• Update and continue identifying technologies and needs for SMPI

(1st year deliverable)

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Technology Development Ideas

• Solicited from technology providers, industry representatives, academia, etc.

• Anticipating the process will include the submittal of one page white papers

• Smart Machine Tool Advisory Group will provide recommendations for funded efforts

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Contact Information

John Kohls(513) 948-2111

[email protected]

Paul Warndorf(703) 827-5291

[email protected]

Smart Machine Platform Initiative

Coalition on Manufacturing Technology Infrastructure

Paul Warndorf Vice President - Technology

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