Download - 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
Self-FormingEnterprises
First ProductCorrect
First Product Correct
Intelligent, Adaptable
Equipment & Processes
Intelligent, Adaptable
Equipment & Processes
ProductRequirements
ProductRequirements
Product & ProcessDefinitions
Product & ProcessDefinitions
Product & ProcessDescriptions
Product & ProcessDescriptions
TransparentExchange ofInformation
TransparentExchange ofInformation
Modeling/SimulationDecisions for
Total Manufacturing
Modeling/SimulationDecisions for
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
First Part CorrectCapable Processes
Self-FormingEnterprises
Self-FormingEnterprises
First ProductCorrect
First Product Correct
Intelligent, Adaptable
Equipment & Processes
Intelligent, Adaptable
Equipment & Processes
ProductRequirements
ProductRequirements
Product & ProcessDefinitions
Product & ProcessDefinitions
Product & ProcessDescriptions
Product & ProcessDescriptions
TransparentExchange ofInformation
TransparentExchange ofInformation
Modeling/SimulationDecisions for
Total Manufacturing
Modeling/SimulationDecisions for
Total Manufacturing Self-Maintaining &Self-Monitoring Systems
Self-Maintaining &Self-Monitoring Systems
AssemblyPart
Product
AssemblyPart
Product
First Part CorrectCapable Processes
First Part CorrectCapable Processes
Self-FormingEnterprises
Self-FormingEnterprises
First ProductCorrect
First Product Correct
Intelligent, Adaptable
Equipment & Processes
Intelligent, Adaptable
Equipment & Processes
ProductRequirements
ProductRequirements
Product & ProcessDefinitions
Product & ProcessDefinitions
Product & ProcessDescriptions
Product & ProcessDescriptions
TransparentExchange ofInformation
TransparentExchange ofInformation
Modeling/SimulationDecisions for
Total Manufacturing
Modeling/SimulationDecisions for
Total Manufacturing Self-Maintaining &Self-Monitoring Systems
Self-Maintaining &Self-Monitoring Systems
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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
Local Knowledge • Health• Accuracy• Dynamic Information• Tooling & Fixturing
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
MaterialsSensorsDesignNanotech.
? ?
?
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
MaterialsSensorsDesignNanotech.
? ?
?
• 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
Paul Warndorf(703) 827-5291
Smart Machine Platform Initiative
Coalition on Manufacturing Technology Infrastructure