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Tekmovanje mladih raziskovalcev

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					     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 !

				
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