newtek nº 108 | Machine tool sector and advanced manufacturing

INTERVIEW BIEMH: Machine tool and Advanced manufacturing

PROJECT Technology for automatic machine tool verification

SCIENCE, TECHNOLOGY AND KNOWLEDGE

THE EXPERT’S VIEW Machine tools and the fourth industrial revolution

JUNE 2018 | No. 108 ENGLISH EDITION

Machine Tool sector and Advanced Manufacturing

INTRODUCTION Nowadays, the machine tool sector is considering where it stands in relation to the so-called “Industry 4.0” revolution that offers multiple possibilities resulting from an ever-growing digitisation of products and processes.

There are many possibilities from a technological perspective, although the question that potential buyers and users of these machines are asking is “how can I benefit from them?” In this edition of newtek we address a number of key elements to apply Industry 4.0 technology to the machine tool business. It also contains information on the 30th edition of BIEMH.

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INDEX

THE EXPERT’S VIEW

C04 Machine tools and the fourth industrial revolution

INTERVIEW

C06 BIEHM: Machine tool and Advanced manufacturing

NEWS

PROJECTS

C08 ONA incorporates C12 Technology for automatic Industry 4.0 technologies machine tool verification to its processes C10 Industry 4.0: Enabling technologies for smart machines

C14 IK4-TEKNIKER’s commitment to laser as a vector for advanced manufacturing

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THE EXPERT’S VIEW JAVIER ARZAMENDI & AITOR ALZAGA

Machine tools and the fourth industrial revolution THE EXPERT’S VIEW Aitor Alzaga.

Coordinator of Industry 4.0 at IK4-TEKNIKER

Javier Arzamendi.

Coordinator of the Machine Tool sector at IK4-TEKNIKER

We are currently feeling a certain sense of expectation with regard to promises associated with technologies related to the so-called fourth industrial revolution.

More progress has been made in recent years in the production of multi-functional machines featuring several processes that can perform a larger number of operations in only one run without manipulating parts.

Another issue that was taken into account only a few years ago has to do with machine energy efficiency. Machines must be designed and dimensioned to reduce life cycle costs to the greatest possible CUSTOMISATION extent and operate according to stringent OF PRODUCTS environmental regulations.

The Industry 4.0 reference model applied to machine tools The challenge the machine tool business is currently facing consists in how to approach the so-called “Industry 4.0” revolution and the many opportunities it offers with regard to the fact that more products and processes are being digitised.

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In order to properly structure an analysis on “what is it I can to make my company more competitive and what features does a machine have to offer me”, it is better to have a reference model as shown in the next figure.

SHORTER LIFE CYCLES

AVERAGE LIFE CYCLE PRODUCTION COSTS

MACHINE OPERATORS

MANUFACTURER SERVICES

FLEXIBLE RECONFIGURABLE

MULTI-FUNCTION / INTEGRATION

AUTONOMY AVAILABILITY

INTEROPERABILITY / OPEN

EFFICIENT

PRODUCTION MODEL | MACHINE USER FOCUSED ON PEOPLE

Consequently, progress has been made thanks to new materials, less coolants, recycling and high-performance components resulting, among other things, in the need to use less shopfloor space.

From a technological perspective, there are many possibilities, although the question that the potential buyers and users of these machines are asking is how can they benefit from them? There is no easy answer, and this will obviously depend on each individual case.

ENABLING TECHNOLOGIES

FLEXIBLE AUTOMATION

VIRTUAL MACHINE

HEALTH ASSESMENT

PROCESS OPTIMISATION

MACHINE FLEET MANAGEMENT

This model specifically refers to a machine tool case of a generic Industry 4.0 model used by IK4-TEKNIKER to diagnose and identify opportunities connected to Industry 4.0.

This reference model seeks to guide machine tool buyers and users to evaluate the most interesting technological features of each individual case. Procurement criteria are not homogenous and may vary as a function of the business strategy established for each particular case and also with regard the production model addressed by the strategy.

With regard to possible supporting technologies, listed hereunder are those that could be potentially considered to be more relevant: • A flexible and easy-to-reconfigure automation allowing, for instance, parts to be loaded and unloaded in production environments characterised by frequent turnovers of components arriving at the machine in containers.

• “A virtual machine” allowing for machine-process simulation and modelling that drastically reduces set-up stages for new processes.

• “A Health assessment” of the machine which, based on a characterisation test series, delivers practically continuous, real-time information on the condition of critical machine components that can be supplemented by selfcalibration mechanisms for machine tools which only in a matter of minutes allows a verification to be carried out with regard to machine errors so that, should any tolerance biases be found, the unit can calibrate itself and carry on machining with greater accuracy.

• Process optimisation based on simulation models that are incorporated to machine monitoring so that decisions can be taken autonomously and intelligently with regard to process parameters and the dynamic conditions of different mechanical components that features real-time machine OEE (“Overall Equipment Efficiency”) monitoring capabilities to permanently update the operator/supervisor with regard to possible trends that might produce potential incidents.

It also helps the operator to discover root causes behind efficiency losses by searching for correlations between OEE and the different variables that could be related to its components (efficiency, availability and quality) by means of statistical and data mining tools.

• Health condition is monitored locally together with associated data that can be exchanged with the machine manufacturer to offer added value services such as predictive maintenance.

We can look into how these technologies influence the attributes of the production model and ascertain to what extent they are actually in line with the drivers of my business. It has been noted that all produce the same impact.

FLEXIBLE AUTOMATION

VIRTUAL MACHINE

HEALTH ASSESMENT

PROCESS MACHINE FLEET OPTIMISATION MANAGEMENT

FLEXIBLE RECONFIGURABLE AUTONOMOUS AVAILABILITY EFFICIENT INTEROPERABLE OPEN FOCUSED ON PEOPLE

If, for instance instance, my business is related to the automotive sector, If sector autonomy and efficiency will be my main focus, which means that machines will have to be equipped with suitable sensors to deliver autonomy and high levels of availability.

On the other hand, having a solution that will allow me to optimise a process will provide me with a differential element relative to my competition.

If my business is related to the aeronautical sector, I will require production solutions that allow me to make and launch new parts in a first attempt.

Concepts such “virtual machine” can be very helpful. Or other things such as “flexible automation”, for instance, can transform certain automations that were unattainable into something far more more feasible nowadays.

It must be stressed that there are two characteristics: “Interoperable/Open” and “Focused on people” that should take into account any kind of technological solution.

Lastly, thought should also be given to another concept, namely, technological maturity, as it impinges on technological supply and demand; At this point in time, and due to the potential opportunities that are apparently available, multiple stakeholders are becoming involved to supplement a more traditional supply although we must bear in mind that not all of them will survive.

On the other hand, and from the point of view of somebody that buys and uses a machine, an organisation must be ready to capitalise on a few or many of the technologies that are being offered.

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INTERVIEW Mª CARMEN GOROSTIZA

BIEHM: Machine tool and Advanced manufacturing Mª CARMEN GOROSTIZA Director of the Machine Tool Biennial (BIEMH)

Mª Carmen Gorostiza has been working for the Bilbao Exhibition Centre (BEC) for more than 25 years. Her career has always been linked to industrial trade fairs focused on metal-mechanical manufacturing (subcontracting, welding, smelting, machine tools, etc.). It was in 2012 when she was appointed director of the Machine Tool Biennial (BIEMH). During this interview, she explains a number of new development visitors will come across at this trade fair.

The Spanish Machine Tool Biennial reaches its 30th edition.

What role has been played by the Basque Country as a pole of development for the machine tool sector and industrial manufacturing business?

The Bilbao Exhibition Centre is deeply rooted in the Basque Country and has been firmly committed to supporting local companies and boosting the economy since it was born 60 years ago.

Therefore, it is no coincidence that our trade fairs are closely connected to the industrial sector and stand alongside other European events with the support of a strong entrepreneurial and associative structure and a clear focus on exports and innovation in terms of services and products.

Thanks to a long-standing track record (dating back to 1961), the International 6 | NEWTEK JUNE 2018

Machine Tool Biennial is a highly prestigious event. It was born as the first monographic trade fair of the Machine tool business in Spain. Although we all know that trade fairs are fundamental in terms of commercial and internationalisation strategies for companies and that they give visibility to and contextualise different sectors, the effect is reciprocal. The sector itself lends strength to each call and, as we say at BIEMH, “you make it big”. Clearly, our slogan “You make it big” is an allusion to the strength of our exhibitors, most of whom are based in the Basque Country.

When abroad, our sales pitch says that visiting BIEMH is much more than going to a trade fair as all the leading manufacturers are located in our area of influence, i.e., within a radius of approximately 100 kilometres. In fact, it is thanks to these companies that the

next edition of BIEMH will be a very special occasion, not only because of reaching edition number 30 but also because it will be a major celebration of how companies have successfully dealt with the crisis and adapted their processes to these new times.

Our exhibitors occupy a solid position in the market thanks to their outstanding technological developments to be showcased, yet again, at the Bilbao Exhibition Centre starting on May 28. In my capacity as director of this trade fair since 2012 (although my involvement with industrial fairs dates back even further) I must say that I feel very proud of a sector that has endured and managed to cope with a very difficult fi nancial situation by developing an amazing vision with regard to how the future has to be addressed.

As IK4-TEKNIKER has regularly participated in the event it can be rated as a historic BIEMH participant. What could you say about the technology centre’s track record at the trade fair?

Research centres are crucially important as regards boosting innovation and competitiveness applied to machine tools and industrial manufacturing.

As far as IK4-TEKNIKER is concerned, both the organisers, exhibitors and visitors participating in the event, believe that this organisation’s presence is not only very valuable but also represents a major technological contribution. Industry 4.0 has reinforced the competitive position of the most competitive companies and, in this particular scenario, technology centres are strategic players where ICTs can be developed and promoted. IK4-TEKNIKER’s role as a driving force boosting knowledge transfers has transformed the organisation into a cornerstone to facilitate further growth and progress in a modern economy.

Could you talk about some of the main innovations that will be showcased during this edition?

The Biennial is a “trade fair on manufacturing for manufacturing”, where innovation, as the true driving force behind Industry 4.0, will be one the key actors. All sectors shall be represented by leading companies that are already

getting their cutting-edge technologies and services ready to make them more accessible for thousands of professionals from more than 50 countries that will be visiting the fair starting on the 28th and are concerned about obtaining as many benefits se possible from the so-called “Fourth Industrial Revolution”. This year, for instance, there will be solutions on display related to components and fittings (26%), stock removal machinery (22%), tools (15%), forming machinery (14%), robotics and automation (9%), metrology and quality control (9%) and other machines (5%).

Hall 4, moreover, will be renamed “Hall 4.0” as it is where new manufacturing practices and approaches to differential space will be on display. BeDIGITAL is one of the new events addressing digital transformations in the industry. Digitisation was already present at BIEMH in recent editions. Henceforth, it will be possible to address issues related to this transversal tool during a monographic forum featuring an exhibition, lectures and sales presentations.

This space will also house ADDIT3D. The third edition of the International Exhibition on Additive Manufacturing and 3D will present a more extensive range of additive manufacturing equipment and machines for final parts and a number of very interesting developments connected to industrial applications as well as a programme of lectures. Additionally, the IMIC-Industrial

Maintenance Innovation Conference will address Industry 4.0 principles and how they can be applied to predictive and advanced maintenance.

What role will digitisation and Industry 4.0 play at the exhibition?

Over the years, the Machine Tool Biennial itself has been gradually transformed by all of these concepts to become Spain’s biggest platform focused on advanced manufacturing. The influence of Industry 4.0 was already felt in previous editions through our commitment to further embrace this new scenario of smart manufacturing.

Although it is not the first time that we have assisted companies in their efforts to change, we are playing an active role and have witnessed significant transformations in the industrial world. I don’t think I’m wrong if I say that the upcoming BIEMH will probably one of its most ambitious editions ever. Industry 4.0 is revolutionising production practices and the way services are offered. It also offers companies very interesting prospects in terms of growth and competitive improvements. I therefore hope that during these five days of BIEMH, BeDIGITAL, ADDIT3D, IMIC and WORKINN, the Forum on Industrial Training and Employment, we shall be able to deliver key elements to successfully manage the new “connected factory”.

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ONA incorporates Industry 4.0 technologies to its processes IK4-TEKNIKER is developing a control system based on smart sensorics to increase process stability for a new family of machines made by the Basque manufacturer ONA. Intense competition in international markets requires the design of smart, flexible and accurate systems capable of increasing productivity and reducing costs.

4.0 concepts to be fitted with automatic processes for the purpose of enhancing the process itself and exchanging information via the acquisition of signals delivered by multiple sensors.

In this scenario, the IK4-TEKNIKER technology centre is working with ONA, a manufacturer of electroerosion equipment, on the design of automatic control systems to develop a new range of highly stable machinery to deliver ultra-precise end results.

This information system will be designed to provide a virtual, real-time simulation of the machine’s behaviour based on the data supplied by its sensors.

More specifically, the technological centre aims to create a new automatic process stability control system to optimise results by installing sensors that provide reliable information on machine operation parameters.

“This system is based on using multiple sensors and a self-calibration algorithm to achieve a stable, flexible, energy-efficient and environmentally-friendly electroerosion process. One of the most outstanding characteristics of this system is that as processes are optimised whilst manufacturing is underway, there are less rejects”, says the researcher in charge of the project at IK4-TEKNIKER, Eneko Gómez-Acedo.

To achieve this goal, technology centre researchers are developing a solution based on Industry

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“The implementation of this new system will guarantee process stability and make it possible to reduce the cost of the parts to be made thanks to a minimal reject rate”, adds the researcher.

In addition to quality improvements, the fact that multiple data will be compiled during the process will allow valuable information to be obtained whilst manufacturing. Moreover, conclusions will be drawn, trends will be identified and traceability will be improved.

The end results of this project will allow ONA to implement the new Industry 4.0 paradigm, whose ultimate goal consists in raising productivity.

It will be possible to use the new range of machines developed through this project in industrial sectors where high-precision parts are very demanded such as aeronautics, renewables, shipbuilding or machinery for civil works.

NEWS

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NEWS

INDUSTRY 4.0

Enabling technologies for smart machines Flexible automation, modelling and machine-process simulation, machine Health assessment, process optimisation and machine fleet management are some of the enabling technologies proposed by IK4-TEKNIKER to be incorporated to machines.

Industry 4.0 has been incorporated to manufacturing processes at medium and large size companies.

The challenge currently being addressed by the machine tool sector is related to where it stands in relation to the so-called “Industry 4.0” revolution that offers multiple opportunities generally resulting from an ever-growing digitisation of products and services.

From a technological perspective, there are many possibilities, although the question that potential buyers and users of these machines are asking is “how can I benefit from them?” The answer will depend on each individual case.

In order to structure the analysis on “what could make my company more competitive and what kind of a performance requirements h ld my machine h should meet”, it would be useful to have a reference model as shown in the following figure.

CUSTOMISATION OF PRODUCTS

SHORTER LIFE CYCLES

AVERAGE LIFE CYCLE PRODUCTION COSTS

MACHINE OPERATORS

MANUFACTURER SERVICES

It must be stressed that this model is an adaptation to the machine tool heading of the general Industry 4.0 model used at IK4-TEKNIKER to diagnose and identify Industry 4.0 opportunities.

FLEXIBLE RECONFIGURABLE

MULTI-FUNCTION / INTEGRATION

AUTONOMY AVAILABILITY

INTEROPERABILITY / OPEN

EFFICIENT

FOCUSED ON PEOPLE

PRODUCTION MODEL | MACHINE USER

ENABLING TECHNOLOGIES

FLEXIBLE AUTOMATION

VIRTUAL MACHINE

HEALTH ASSESMENT

PROCESS OPTIMISATION

MACHINE FLEET MANAGEMENT

Here there is a description of the most relevant enabling technologies that users of machine tools can resort to as a support.

Flexibility and reconfigurability: Flexible robotics The fi rst operation performed in a machining process consists in loading the part on predefi ned tooling. This is usually done manually, although when automated, special

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systems are built for this operation that are predefi ned by the specific features of the parts. This explains loading systems are barely flexible and very difficult to reconfigure.

IK4-TEKNIKER can offer a comprehensive solution (bin picking, artificial vision, trajectory generation, force control, etc.) that allows companies to increase machine productivity and reduce costs associated with loading and unloading operations that are usually performed manually.

The solution is geared towards companies that machine parts on flexible manufacturing cells and machining centres.

Virtual machines: Modelling and machine-process simulation The ultimate goal is to carry out in-depth research on technologies used for simulation (of machines and processes), data analysis and monitoring to configure a sufficiently resilient hybrid modelling platform to allow machine manufacturers and users significantly optimise (in terms of time and cost) their designs, ramp-up and production life cycles and also meet new requirements by simultaneously upgrading their quality and reliability ratios.

Health assesment Machine monitoring performed by efficient, sensitive, distributed and global sensors featuring multi-variable monitoring devices allows users to obtain continuous real-time information on the condition of several machine components, production process status and the variable environment that surrounds production.

In addition to fitting internal and external sensors, IK4TEKNIKER proposes that a number of very simple and rapid machine tests be run to discover the condition of a machine by analysing the evolution of seve- ral parameters over time. This is what IK4-TEKNIKER calls “Fingerprint”.

Signals describing how the machine is being used by compiling for instance, data on speed, power and temperature readings delivered by heads and guideways FINGERPRINT 0 FINGERPRINT 1 FINGERPRINT 2 FINGERPRINT N

This allows for machine operational checks and controlled health assessment.

This system allows machine health assessments to be made whenever operational and maintenance decisions must be taken. You can also anticipate the presence of geometric errors on parts by moving towards “zero defects”, which is essential, particularly if highvalue parts are involved.

Process optimisation Until now, theoretical simulation models analysed the machine tool and the machining process independently, without any kind of interaction.

Nowadays, however, platforms equipped with different simulation models are being developed to globally analyse machines and their machining processes.

This technology is connected to a new simulation concept that embraces both the process and the machine.

Simulation models, moreover, have been in the design stage as predictive models to obtain information prior to performing an operation. Nowadays, however, there have been significant changes as results can be used for online monitoring during the machining stage.

Multi-target optimisation strategies have been developed so that, based on information compiled in real time and on a number of pre-established models and patterns, production resources can take autonomous and smart decisions with regard to process parame-ters and dynamic conditions of various mechanical components, to ensure, in each particular case, that production targets are achieved (costs, production, power consumption, machine conditions, etc.). This process optimises manufacturing practices.

Fleet management: From a single machine to fleet management In a fi rst step, machines must be fitted with sensors and monitoring devices covering different simulation models, so the machine and the process can operate in a coordinated manner (in a closed loop) and be enhanced by “Fingerprint” trials to optimise processes and perform health assessments on different machine components.

Once this important step has been taken, the next move consists in ascertaining the condition of a manufacturer’s entire fleet.

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PROJECTS

Technology for automatic machine tool verification A patented solution for the verification of medium and large mechatronic systems

IK4-TEKNIKER develops a patented solution for the automatic and integrated verification of medium and large machine tools.

In certain sectors such as, for instance, wind power and aeronautics, the current trend is to produce larger parts although preserving the accuracy of their predecessors. This explains why larger machine tools with a higher degree of accuracy throughout their work volume are required. As machine tool volumes grow, however, it becomes increasingly complex to verify the g geometry of their systems.

T Traditional verification technologies such as interferrometry, electronic level gauges or perpendicularity ssquares are no longer agile enough when dealing with llarger machines. This is where IK4-TEKNIKER discovered the need to develop a verification tool for medium and large machine tools.

In order to deliver a solution that allows companies to overcome this problem, i.e., so they can guarantee the geometry and functionality of their machine tools, IK4-TEKNIKER decided to put its stakes on the multilateration technique

and develop a procedure so that users can measure ure ma machine tool geometry throughout the entire work volume me quicker and with a greater degree of accuracy compared to other technologies available nowadays.

By using a Laser Tracker and processing measurements by means of the multilateration technique, IK4-TEKNIKER is currently able to offer an in-house solution for the verification of large machine tools.

Moreover, and as a collaborating firm of the German company ETALON AG, IK4-TEKNIKER can also provide their commercial solution called Laser Tracer for machine tool verification and volumetric compensation.

Measuring procedures using the IK4-TEKNIKER and ETALON AG solutions require that staff carry out the measuring procedure in full. This detail excludes both solutions as a resource for the automatic verification of large mechatronic systems.

This is why, IK4-TEKNIKER TEKNIKER has gone one o step further and has developed a solution n that has its own patent (“InIn tegrated grated multila multilateration for machine tool ol automatic automati tomatic vev rification”) that at automatically automatically l verifi ve verifies ifies the geometry of a machine tool throughout itss entire work volume by installing a Laser Tracker system as if it were just another machine tool.

Users of this technology The users of this technology are manufacturers and users of medium and large volume mechatronic systems linked to the machine tool business.

The solution allows for the verification of medium and large volume machines that must guarantee a level of accuracy under 0,1 mm throughout their entire work volume and at all times, automatically. It can also be incorporated to the machine in the form of an additional functionality.

PROJECTS

IK4-TEKNIKER’s commitment to

laser

as a vector for advanced manufacturing The Laser for Manufacturing Lab provides a 360º view of laser technology and how it is applied

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IK4-TEKNIKER has developed a global solution based on laser technologies applied from an integral perspective in the field of advanced manufacturing.

Advanced manufacturing is evolving in parallel with sectors that are strategic in terms of technological development such as biomedicine or the automotive or aeronautical sectors, among others, which are areas that demand high added value components capable of offering a high degree of accuracy and meeting strict safety standards.

To meet these demands, IK4-TEKNIKER has developed a global solution based on laser technologies that are applied from the global perspective of advanced manufacturing; the design and manufacture of equipment and components; additive manufacturing with inspection and measuring.

The initiative has resulted in the “Laser for Manufacturing Lab”, an offer focused on providing comprehensive solutions based on a specialised and integral knowledge of this technology.

The Laser for Manufacturing Lab provides a far better and extensive instrument to reach out to the industry and meet specific advanced production needs via the options resulting laser technology that delivers a 360º vision on the laser technology and how it is applied.

This initiative covers a joint and coordinated offer comprising all the solutions developed at IK4-TEKNIKER in this field and can be classified as follows:

CUTTING

METAL WELDING

TEMPERING / ANNEALING

LASER CLADDING

TECHNIQUES

DEVICES / EQUIPMENT

Gas-assisted melting Remote

Conduction “Keyhole” Remote

Fixed optics Oscillating beam

Powder cladding Wire cladding

APPLICATIONS

MATERIAL PROCESSING MACRO

• Component deburring

• Identical alloys

• Hardening

• Surface reinforcement

• Precission micro-cutting

• Dissimilar materials

• Annealing

• Mould recovery&repair

• Softening

• Coatings

• 3D cutting

• Assistance in stock removal

Simulation

Design & manufacture of optomechanical components

Optical simulation Thermo-mechanical simulation (FEM)

Beam modifiction Nozzles Mountings Heads

Integrating sources in complete solutions

Complete high productivity solutions

Process monitoring & control systems

ADDITIVE MANUFACTURING

& shaping processes

POLYMER WELDING

UNIÓN MATERIALES DISÍMILES

TECHNIQUES

Combustion Ablation Shock waves

Quasi-simultaneous (Scanner) Contour Simultaneous

Quasi-simultaneous (Scanner) Contour Simultaneous

APPLICATIONS

Processes CLEANSING / STRIPPING

• Paint, and coating

• Similar thermoplastic

• Thermoplastic-metal

stripping, etc.

• Removing rust, grease,

contaminating substances, etc.

materials

POWDER LMD Laser nozzles / Heads for powder and wire LMD WIRE LMD Complete solutions for the additive manufacturing of large structures by LMD Hybridisation of LMD processes with other manufacturing technologies

INSPECTION AND MEASUREMENT

• Dissimilar metals

• Dissimilar thermoplastic

materials

Large-scale technologies (Tracker, interferometry, tracer)

APPLICATIONS

TECHNIQUES

MICRO TEXTURISING

MICROMACHINING

MICRODRILLING

MARKING

Quasi-simultaneous (Scanner)

Quasi-simultaneous (Scanner)

Single pulse Percussion Trepanning Helical

Quasi-simultaneous (Scanner)

• Micro-moulds

• Filters

• Decoration

properties

• Tool profiling

• Valves

• Traceability

• Replication

• Chip breaker

• Improving tribological

• Super hydrophobic surfaces

Short range technologies (Triangulation, structured light, confocal, time of flight)

Laser systems for process monitoring and control

OTHERS Consultancy

Training

Industrial implementation of laser systems

Course on “Industrial laser applications” Specific on-demand courses “Hands-on” Training at IK4-TEKNIKER or at customer facilities

Diagnosis of laser beams Characterisations / Safety Fine-tuning of industrial processes

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