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u www.tugraz.at
Smart Machine - Smart Factory - Smart CompanyA bottom-up approach to Digital Production
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
1
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
2
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusions
• Discussion
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
3
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusion
• Discussion
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History of Development in Mobility (1992 -2017)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
4
http://www.autobild.de/videos/video-wv-golf-3-1991-10927401.html
https://ecomento.tv/modelle/tesla-model-3
https://www.volkswagen.at/golf/golf-gti
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History of Development in Production (1992)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
5
Source: H.J. Klein (1992),Journal ZwF
Source: M. Stoaks, W. Klar (1992), Journal ZwF
Source: TDV-CIM (1992), Journal ZwF
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History of Development in Production (2017)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
6
https://www.tesla.com/de_AT/gigafactory
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Development of the national debt in Austria
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
7
Unfortunately not fake news
1990 EUR 76,518,000,000 56.2 % of the GDP
1995 EUR 119,834,000,000 68.0 % of the GDP
2017, April EUR 295,883,195,053 84.6 % of the GDP
The national debt of Austria per 22/04/2017
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
8
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusion
• Discussion
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Smart Machine - Attributes
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
9
Economical Adaptable
Intelligent Open
Universal
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Smart (Grinding)-Machine @ IFT (TU Graz)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
10
Photo: Lunghammer
Design Parameters:
Overall dimension:6 m x 3.5 m
Maximum size of the work piece:Ø 520 mm x 1.500 mm
Controller: SINUMERIC 840Dsl
Main grinding spindle:P = 72.5 kWnmax = 6.500 min-1
vmax = 220 m/s
Maximum grinding wheel dimension:Ø 650 mm x 600 mm
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Interior of the Research Grinding Machine
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
11
Design Parameters:
Second grinding spindle:nmax = 4.500 min-1
Second grinding wheel dimension:Ø 600 mm x 200 mm
Photo: Lunghammer
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Smart (Production) Machine Principles: Design / Tool / Process
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
12
Design
Tool
Process
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Design of Machine Structure
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
13
Machine bed under
construction(Component I)
Component II
Temperature sensors inside
Bed cured and reversed
Light weight carriage
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Far
Fat
ID=201 WHENEVER (($R1<>0) AND ($R50==1)) DO $AA_OVR[X1]=$R1
Design of Adaptive Control(Project AGriPro)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
14
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𝒗𝒇𝒓
𝑭𝒕
𝑪𝟑
Results – Improvement of Productivity
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
15
Process and Control Parameter:• Δt𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑒𝑟 = 0,050 s• f𝑚𝑒𝑠𝑠 = 500 Hz• d𝑤 = 44 mm• b𝑒𝑓𝑓 = 22 mm
• v𝑐 = 40 m/s• K𝑝 = 15
• K𝑖 = 80• K𝑑 = 2• 𝐶1 = 100• 𝐶2 = −0,70
𝑭𝒕 = 𝑪𝟏 · 𝒗𝒇𝒓(𝟏+𝑪𝟐)
· 𝑪𝟑
𝑪𝟑 =𝒃𝒆𝒇𝒇
𝒗𝒄·𝝅 · 𝒅𝒘𝟔𝟎
(𝟏+𝑪𝟐)
𝑭𝒕/𝑵
𝒗𝒇𝒓 / mm*min-1
Thermal damaging
No thermal damaging
+ 138%
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Design Man-Machine-Communication (MMC)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
16
Minister for Infrastructure and Innovation
Mag. Jörg Leichtfriedvisits IFT in January 2017
Microsoft HoloLens as a wearable for MMC
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Tool: Precision Shaped Grain (3M-Cubitron® II)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
17
Source: Helmut Gaisberger, 3M GmbH (Suisse), Grinding congress 2017 in Stuttgart-Fellbach
Conventional
ceramic grain
• Lower process temperature
• Continuous conditioning
(shaping, sharpening) of the
grinding wheel
3M Cubitron® II
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Non-circular Grinding
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
18
Oscillating Non-circular grinding RPM-synchronous Non-circular grinding
Cam
nG : nW = 1 : 1
Polygon
nG : nW = 3 : 2
Square
nG : nW = 2 : 1
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Grinding Wheel Profile
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
19
Work piece profile
Grinding wheel
• The grinding wheel profile results for one plane as the envelope of the commontangent of the wheel itselfon the one hand and on the other hand of the rolling off work piece.
• Mathematic iteration is essential.
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Process: Preformed 3D-Grinding
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
20
Shaped profile under load
Theoreticalprofile
Preformedprofile
Final profileunder load
Source: Kolbenschmidt
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
21
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusion
• Discussion
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Smart Factory as a concert hall
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
22
Workflow,
Framework Source: www.wienersymphoniker.at Products: P1, P2, P3
P1
Smart
Machine
Smart
Machine
Smart
Machine Smart
MachineSmart
Machine
Smart
Machine
P3
P2
P1
P3
P2
P3
P2
P2
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Smart Factory at TU Graz
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
23
Univ.-Prof. Dr.techn. Rudolf PichlerHead of the Smart Factory
Pilot Factories 4.0Initiative of Austrian Research Promotion Agency
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What will be produced?
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
24
Drive-System (Gearbox) for E-Axles
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
25
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusion
• Discussion
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Smart Company – Node within an internationalproduction network
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
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Smart Production Graz – Initiative within the Field of Expertise Mobility and Production
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
27
smartfactory
Dependable Things Big Data Analytics
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Pro2Future – New Competence Centre(JKU Linz, Profactor, TU Graz)
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
28
It started in April 2017.
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Ö-WGP – Austrian Association of Professors in Production Scienceat TU Wien, TU Graz, MU Leoben, JKU Linz
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
29
Ö-WGP
Hubert Biedermann
Friedrich Bleicher
Bruno Buchmayr
Alois Ferscha
Detlef Gerhard
Franz Haas
Clemens Holzer
Ernst Kozeschnik
Stefanie Lindstaedt
Paul Heinz Mayrhofer
Paul O'Leary
Andreas Otto
Christian Ramsauer
Ralf Schledjewski
Peter Schumacher
Wilfried Sihn
Christof Sommitsch
Siegfried Vössner
Klaus Zeman
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
30
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusion
• Discussion
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Conclusion
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
31
SmartCompany
(Communication)
Smart Factory(Big Data, Security,
Connectivity)
Smart Machine(Process knowledge, Construction,
Precision, Mechatronics)
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Agenda
Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
32
• 25 years – What has changed within this period?
• Smart Machine
• Smart Factory
• Smart Company
• Conclusion
• Discussion
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Univ.-Prof. Dipl.-Ing. Dr.techn. Franz Haas
33
Precision guarantees our future.