Research group: Dynamic Intelligent & Integrated Technological Systems & Devices Report: 2004 - 2008 Proposal: 2009 - 2014 Our mission ! Contribution to the science in the field of Manufacturing Technology and related sub-systems and processes Transfer the knowledge to industry Introducing the PhD students into research work Enrichment of university education with new knowledge Promotion of science Contribution to socio-economic and cultural development Our vision ! To develop the comprehensive model of INTEGRATED - INTELLIGENT & AUTONOMUS MANUFACTURING SYSTEM and supporting processes as answer on requirements on global market and to move towards INTELLIGENT e – F@CTORY ! Action ! Part I: Report - achievements in past period Part II: Outstanding achievements of research group Part III: Future research work Overall structure of research field Automation Monitoring Manufacturing system Modelling AMPLIFIER And processes Optimization Control Programming %100(C, 18.10.102) N10 G00 G90 G54 X0 Y200 B0 Scheduling Part production Past research work: Modeling, simulation, optimization, programming and control of manufacturing system, machining processes, related support systems and developing of new fields of applications Part I: Report - achievements in past period Some significant deliveries: 1.Universal evolutionary (GA, GP) based system for: Programming of CNC machine tools 3D–solid model IN Finished part OUT Results: Totally automatic tool path generation Intelligent way to find out optimal tool path No manual intervention needed Part I: Report - achievements in past period Programming of CNC cutting machines (laser, plasma, water-jet, engraving, plotting…) Results: Location of parts Laser beam path Cutting sequences Optimal solutions Cutting type Material & energy savings Part I: Report - achievements in past period Simulation and programming of robots movement in manufacturing environment (shop floor) North E End point West East S Start point South Best trial from Generation # 0 Obstacles- machine tools Starting point- o Can’t find the way S rough part storage E End point- storage o Totally disoriented Parts in storage- o But learned from this trial mission completed Part I: Report - achievements in past period Simulation and programming of robots movement in manufacturing environment (shop floor) Different environment - cooperation Best trial from Generation # 23 Mission completed Intelligent, autonomous Dynamic environment Part I: Report - achievements in past period 2. Intelligent NN based CNC control for milling machines NEW CAD/CAM system- manufacturing CAD part NN model PC teaching module Optimal milling strategy NN device Manual input NEW Internal interface Decoding Position Function Interface memory memory X, Y, Z M, S, T Interpolation Function W M program program Comparison Position measuring Amplifier NN-CNC unit Finished part Result: Self programming CNC milling machine Part I: Report - achievements in past period 3. Intelligent (GA/NN) on-line control of milling machine 00 10 80 0 x F Recommended 60 0 0 40 0 20 y F F z cutting 0 0 -20 0 -40 conditions dynamometer amplifier ML IE A PIF R f, RD, AD, vc LabView Tool milling process microscope + - measured wb forces ANFIS-modellng Fx,Fy,FF z Adaptive control scheme Experimental set-up clip Results: Collecting & optimization of cutting condition On-line control of milling machine Part I: Report - achievements in past period 4. Automation of manufacturing processes CLIP On-line automation of high speed blanking (600min-1) Accomplished tasks: Cinematic analysis of press Measurement of temperatures Measurements of forces on FEM analysis press Determination of new Measurement of deformations dimensions Part I: Report - achievements in past period Automatic bar clip The goal of this project was: to develop fully automated bar to demonstrate the efficiency of use of industrial robots and Chaos technology in virtual any industry Part I: Report - achievements in past period 5. Speed controlled hydraulic supply system Goals: • High power transmission • Low energy consumption • Low noise emission • Ease of maintenance • Cost effectiveness Solution: Volumetric control of the hydraulic energy! Steps done: exactly mathematical modelling test rig design determining the appropriate control strategy appropriate signal acquisition and processing method experimental analysis and comparison of results Part I: Report - achievements in past period 6. Development of RP technology and applications in: Simultaneous engineering Reverse engineering Small batch production of prototype parts Functional prototype in 2 days Silicon tools for vacuum casting 8 products in 5 days Savings: 90% of time and 80% of resources according to classical tools Part I: Report - achievements in past period 7. Development of RP technology and applications Hydraulic valves from steel Mould manufacturing by RP using casting sand Casting: ETA co. Cerkno For parts with complex inner shapes Injection pipe Al tool for bath Alloys with low melting production point and vacuum casting Part I: Report - achievements in past period 6. Development of RP technology and applications in: Medicine clip o Patient 36 years o Massive skull injury o CT of skull made o Ti6Al4V implant Benefits: Decrease of surgery time Custom made Implant fits perfect Faster recovery Part I: Report - achievements in past period Preserving of cultural and technical heritage Renovation of old-timers Original (museum) Re-modelling Renovated old-timers Vacuum casting (replica) Part I: Report - achievements in past period Preserving of cultural heritage Scanning Old sculpture (original) Wax model Metal casting (replica) Engraving Milling Part I: Report - achievements in past period National projects for industry Approaching EU-Part II for SMEs Participated 78 companies Budget: 250.000 Euro (2 FTE) Technology part: Jože Balič Delivery: Rules, Methods and practical technical support for EU- market. Preparing Slovenian small companies for EU market (technology, bussines) Part II: Outstanding achievements of research group Application of patent Step-by-step milling (Kaldera co.) Delivery: Increase of tool life (30%) No tool breakage Better surface quality Shortening of machining time Developing Slovenian technical language Detailed explanation Part I: Report - achievements in past period Recognition in Slovenian science community Zois award for 2007 Gold medals Gold medal for Highest scientific award University of Maribor Cranial implant for outstanding achievements in PRODUCTION TECHNOLOGY AND AUTOMATION Member of publishing board Part II: Outstanding achievements of research group Recognition in international science community Editor of International Scientific books Member of International Editor in chief editors board World GP lib. 3 researchers in TOP 50 (out of 3600) Organizer of International Conferences Silver medal with DAAAM zirconia International Most viewed UNI Gliwice vice- 2 fellows- WAMME president article Part II: Outstanding achievements of research group International projects & co-operations Partners: Hoegeschool Gent, Belgium LIOS-Maribor, Slovenia De-Nayer Institute, Belgium CRIF/WTCM, Belgium FEM Engineering, Norway MPC Plastics, Poland University of Minho, Portugal Centifme, Portugal MCO, Holland Part II: Outstanding achievements of research group International projects & co-operations Partners: •Gavle University, HIG •Swedish Maintenance Society •UTEK Danish Maintenance Society, DDV •Belgian Maintenance Society, BEMAS Slovakian Maintenance Society, SSU •Dublin Institute of Technology, DIT •Slovenian Maintenance Society Part II: Outstanding achievements of research group International projects & co-operations Partners: •Hogeschool Utrecht Centrum voor Techniek University of professional education centre for technology •Van der Meer & van Tilburg •European Federation of National Maintenance societies •CSPU Czech Maintenance Society •DDV Danish Maintenance Society •AIMAN •NCC Nederlands Corrosie Centrum •APMI Portuguese Maintenance Society •Transilvania University of Brasov •UTEK Swedish Maintenance Society •University of Celje Solski Center Celje •University of Maribor •Robert Gordon University of Aberdeen International projects & co-operations Establishing: RApid Prototyping and Innovative MAnufacturing Network Part II: Outstanding achievements of research group RAPIMAN network is member of international organization GARPA Global Alliance of Rapid Prototyping Associations Part II: Outstanding achievements of research group Part III: Future research work Task # 1: Developing of Virtual manufacturing system The goals: Modeling of machine tools & equipment clip Searching for optimal machining operation and tools selection clip Delivery: Virtual model of machine tools System for determination of optimal machining sequences and cutting tools sets Virtual machine tool Optimal machining operation and tools set Part III: Future research work Task # 2: Developing of Virtual manufacturing system Goals: Optimal production scenario using evolutionary methods Developing of intelligent system for production cost estimation Delivery: Method & model for intelligent and optimal control of FMS Parts cost estimation method direct from CAD-model Cost estimation from CAD to tool Intelligent production scenario and scheduling Part III: Future research work Task # 3: Building an Intelligent NN-based CNC machine The goals: Developing of NN-based CNC programming system Design of Intelligent CNC control Delivery: Intelligent programming system Prototype of intelligent CNC control Application: Intelligent machine tool (milling, drilling, engraving) CAD Input system 3D part model Output Visual Simulation of tool path Intelligent open CNC milling machine Part III: Future research work Task # 4: Creating a virtual robot model for offline programming using digitalization The goal: Design and construction of an intelligent robotic cell Application: integration in intelligent manufacturing system, prototype design, assembly, welding, free sculptured machining 10 Part III: Future research work Task # 5: Optimization of robotic & assembly system Goal: Optimization of robot and assembly systems by AI Robotic system for manufacturing large prototypes Delivery: System for intelligent assembly by robots Robotic cell for manufacturing of large scale parts Intelligent assembly of gears Manufacturing of large parts 10 Part III: Future research work Task # 6: Developing of Rapid Manufacturing Goals: RP/RM technology evaluation Direct production to costumer order Methods for evaluation of human scan data in medicine Development of custom made surgery implants Delivery: RP/RM evaluation method Direct produced parts for consumer goods according to customer order Custom made surgery implants (skull, mandibula,…) Mandibula implant Evaluation of CT data 10 Part III: Future research work Task # 7: Automation and control Goals: Development of intelligent closed loop control of servo- hydraulic and servo-pneumatic drives Optimization of extruded aluminum alloys on direct press Design of high power transmission capacity at low losses Improve dynamic performance of the drive Raise the reliability and maintainability of the drive Using of exclusively low-cost industrial components To achieve a convenient price-performance ratio of the drive Delivery: Improved operating precision and accuracy of servo drives Reduced influences on the environment for 40% High performance speed controlled hydraulic systems 10 Part III: Future research work 2014 Hvala ! Thank You !