NAME SMART: This asset compiles a series of applications in different fields which provide the machine with advanced features and contribute to a diagnosis and in some cases, intelligence-based action.

DESCRIPTION

SMART: This asset compiles a series of applications in different fields, such as:  Thermal optimisation: Characterisation of the thermal performance of machines based on tests in sensorised machine, thermal modelling of machines using advanced thermal FEM, design of thermoset machines, monitoring and recording of thermal performance of machines, development and implementation of control functions for on-line offsetting of thermal deflections.  Advanced control functions: Development and integration of advanced machine functions based on control parameters and embedded sensors to strengthen the machine’s process, protection and safety features and help the user’s operability: balanced, self-adjustment of axes, protection of heads, detection of abnormal vibrations, process monitoring, etc.  Integration of sensors in critical components: Design and integration of sensorised machine components, aimed at improving the machine’s features and safety and supporting the manufacturing process: heads with integrated accelerometers, screws with temperature sensors and accelerometers, machine structures with displacement sensors, etc. Development of HW and the necessary SW to offer comprehensive solutions, fully integrated in the machine and their control.  On-line supervision of manufacturing process: on-line information, based on CNC signals and sensors, related to whether a machining process is taking place within the admitted parameters, based on previously defined normality models through the data records for a specific part/process.  Optimisation of tool lifetime: prediction of the remaining life of cutting tools for machining processes based on the capture of CNC and sensor signals, issuing a continuous diagnosis of the remaining use time or the number of parts that a tool will be able to machine.  Process quality control: 3D vision camera using structured light technology integrated in the machine. Thanks to the detection, location and comparison SW, the quality of the finished part is controlled, whereby the user may define corrective actions. The suitability of the initial part to the CAD of the target part can also be controlled prior to the process. These applications provide the machine with advanced features and contribute to a diagnosis and, in some cases, intelligence-based action.

FIELDS OF APPLICATION

Digitalization and Conectivity

MOST OUTSTANDING EQUIPMENT AND COMPONENTS

  • CNC controls for the development of thermal deflection offsetting functions through the control of machine-tools.

    CNC controls for the development of thermal deflection offsetting functions through the control of machine-tools.

  • Sensors for integration in machine components (accelerometers, thermocouples, LVDTs, etc.) and associated electronics.

    Sensors for integration in machine components (accelerometers, thermocouples, LVDTs, etc.) and associated electronics.

  • Software for the calculation of thermal performance by finite elements: MSC MARC

    Software for the calculation of thermal performance by finite elements: MSC MARC

  • Thermal testing measurement equipment: displacement, temperature, level sensors, etc.

    Thermal testing measurement equipment: displacement, temperature, level sensors, etc.

  • Vibration acquisition and processing equipment

    Vibration acquisition and processing equipment

SERVICES OFFERED BY THE ASSET

Advising

Advice for the implementation of solutions based on mono and/or multi-objective optimization algorithms for the improvement of processes, machines, supply chains, operator shift planning, maximization of efficiency and minimization of cost in industrial processes, etc.

Balance solution for machine-tool dividers

Development and implementation of balance solutions and protection of dividers based on integrated accelerometers.

Characterisation of the thermal performance of machines through testing

Characterisation of the thermal performance of machines through thermal and environmental testing of machine heating, performed on a sensorised machine to record its temperatures and deflections

Control functions to offset the machine’s thermal deflections

Development of mathematical models to offset machine deflections based on characterisation Design of control functions to offset the machine’s thermal deflections

Design of thermoset machines

Design of machines aimed at the optimisation of thermal performance, reducing heat spots, as well as structural deflections.

Design, integration and processing of sensorised machine-tool components

Design and integration of sensorised machine components to improve the machine features and safety and support the manufacturing process. Development of HW and the necessary SW to offer comprehensive solutions, fully integrated in the machine and their control.

Integration of camera in the machine for control of the initial part and CAD.

Development and integration testing of 3D computer vision systems in machines to control the suitability of the initial part.

Integration of camera in the machine for quality control

Development and integration testing of 3D computer vision systems in machines for quality control.

Modelling, characterisation and thermal optimisation of machines by finite elements

Thermal modelling of machines through calculation by finite elements. Simulation of thermal load and environmental machine heating to calculate the machine’s deflections. Sensibility study of the machine’s components to heat spots and thermal deflections. Proposal and simulation of design solutions for the optimisation of thermal performance and cushioning of the deflections.

Monitoring and protection of machine-tool heads

Monitoring and supervision of head vibrations through integrated accelerometer signals and the machine’s internal control signals to help the manufacturing process and to protect the head through foreseeing wear and tear or detection of collisions.

Optimisation of tool lifetime

Once the required process signals have been collected (CNC and/or sensors), they are analysed and wear models are generated for a certain operation. Then, when these operations are performed, the system informs on the estimated remaining life for a tool.

Research into manufacturing processes (machining) to generate models that enable their status to be controlled in real time.

Once the required process signals have been collected (CNC and/or sensors), they are analysed and normality models are generated for a certain operation. Subsequently, when these operations are performed, the system informs at a machine-level whether the process fulfils the pre-established normality thresholds.

Sensing of ball screws and signal processing

Integration of sensors in ball screws and processing of the signals acquired, along with the machine’s control parameters, to foresee failures and wear in the component.

ENTITY MANAGING THE ASSET

ENTITY MANAGING THE ASSET
FUNDACIÓN TECNALIA RESEARCH & INNOVATION
Contact person:
Karmele Florentino
karmele.florentino@tecnalia.com