1 NEXT GENERATION PRODUCTION SYSTEMS: NEXT Start date:End date: 01 September 200531 October 2009 Duration:4 years Budget:21,745,801 EC contribution:13,999,999.

1

NEXT GENERATION PRODUCTION SYSTEMS:

NEXT

Start date: End date:

01 September 2005 31 October 2009

Duration: 4 years

Budget: 21,745,801 €

EC contribution: 13,999,999 €

IP 011815 NEXT

Presentación al CENIT eEe

NEXT IP 011815 2

NEXT RESULTS Adoption of “green” practices at

overall production equipment design,manufacturing, use and disposal

Quality of life, working conditions,safety and health ofproduction equipment users

Competitiveness for Europeanmanufacturing industry, new ways ofmaking business

Attractiveness of manufacturingsector to all the society

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TECHNOLOGIES

THE GREEN MACHINES

THE MANUFACTURING FRONTIERS

ECONOMIC TRACK

RESEARCH ON KEY TECHNOLOGIES THAT WILL ALLOW BREAKTHROUGHS IN EACH TRACK (Keeping synergism between tracks)

INTEGRATED IMPLEMENTATION OF TRACK RESULTS INCORPORATING KEY TECHNOLOGIES INPROTOTYPES

SPECIFIC TRAININGACTIVITIES ON TRACKTOPICS. DISSEMINATION

OBJ 5

THE USER CENTRIC AUTONOMOUS MACHINES

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sBENEFITS FOR SMEsINDUSTRIES (Builders

and users of productionsystems) & EU

“NEXT GENERATION”PRODUCTION SYSTEMS

NEW

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ND D

ISSE

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NEXT RESULTS Adoption of “green” practices at

overall production equipment design,manufacturing, use and disposal

Quality of life, working conditions,safety and health ofproduction equipment users

Competitiveness for Europeanmanufacturing industry, new ways ofmaking business

Attractiveness of manufacturingsector to all the society

OBJ 1

OBJ 2

OBJ 3

OBJ 4

Prod

ucti

on p

roce

sses

Sim

ulat

ion

Mon

itor

ing,

mea

sure

men

t

Ada

ptro

nics

New

mat

eria

ls

New

arc

hite

ctur

es

Con

trol

s

TECHNOLOGIES

THE GREEN MACHINES

THE MANUFACTURING FRONTIERS

ECONOMIC TRACK

RESEARCH ON KEY TECHNOLOGIES THAT WILL ALLOW BREAKTHROUGHS IN EACH TRACK (Keeping synergism between tracks)

INTEGRATED IMPLEMENTATION OF TRACK RESULTS INCORPORATING KEY TECHNOLOGIES INPROTOTYPES

SPECIFIC TRAININGACTIVITIES ON TRACKTOPICS. DISSEMINATION

OBJ 5

THE USER CENTRIC AUTONOMOUS MACHINES

DEM

ONST

RATO

RS:

Pro

toty

pes

and

new

way

s of

doi

ng

busi

nes

sBENEFITS FOR SMEsINDUSTRIES (Builders

and users of productionsystems) & EU

“NEXT GENERATION”PRODUCTION SYSTEMS

NEW

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ND D

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OVERVIEW OF NEXT PROJECT

NEXT IP 011815 3

Establishing the base of a new generation of autonomous and “user-friendly” machines that will support a much more efficient and comfortable way of working (e.g. automatic recognition of manufacturing tasks and process conditions).

User-centric Autonomou

s MachineTrack 2

Manufacturing

Breakthrough

Track 3

Designing and building the best process-controlled production machines in the world in terms of performance, productivity and achievable quality (2x - 5x improvement in machine tool productivity, increasing accuracy, higher reliability).

Economic Objective

Track 4

New ways of doing business in the production machinery sector. Exploring and defining new ways of selling products AND services, new formulae not currently applied related to ownership of the equipment, payment, financing, new organisation models, etc..

Dissemination and

Training Objective

Track 5

Transferring the research results to interested industrial partners, both users and producers of machines, where training and skill development will be provided.

Green Machine

Track 1

Radical innovation into environmentally friendly production machines. Consider environmental aspects through the entire life-cycle of machines: use of recycled materials for machine elements, reduction of energy consumption at machine use, zero waste produced, dismantling and recycling of 100% machines, and working in non-pollutant machining processes.

OBJECTIVES

NEXT IP 011815 4

NEXT RESULTS Adoption of “green” practices at

overall production equipment design,manufacturing, use and disposal

Quality of life, working conditions,safety and health ofproduction equipment users

Competitiveness for Europeanmanufacturing industry, new ways ofmaking business

Attractiveness of manufacturingsector to all the society

OBJ 1

OBJ 2

OBJ 3

OBJ 4

Prod

ucti

on p

roce

sses

Sim

ulat

ion

Mon

itor

ing,

mea

sure

men

t

Ada

ptro

nics

New

mat

eria

ls

New

arc

hite

ctur

es

Con

trol

s

TECHNOLOGIES

THE GREEN MACHINES

THE MANUFACTURING FRONTIERS

ECONOMIC TRACK

RESEARCH ON KEY TECHNOLOGIES THAT WILL ALLOW BREAKTHROUGHS IN EACH TRACK (Keeping synergism between tracks)

INTEGRATED IMPLEMENTATION OF TRACK RESULTS INCORPORATING KEY TECHNOLOGIES INPROTOTYPES

SPECIFIC TRAININGACTIVITIES ON TRACKTOPICS. DISSEMINATION

OBJ 5

THE USER CENTRIC AUTONOMOUS MACHINES

DEM

ONST

RATO

RS:

Pro

toty

pes

and

new

way

s of

doi

ng

busi

nes

sBENEFITS FOR SMEsINDUSTRIES (Builders

and users of productionsystems) & EU

“NEXT GENERATION”PRODUCTION SYSTEMS

NEW

CO

NTEN

TS

FO

R T

RAIN

ING A

ND D

ISSE

MIN

ATIO

N

ARO

UND P

RO

DUCTIO

N E

QUIP

MEN

T

NEXT RESULTS Adoption of “green” practices at

overall production equipment design,manufacturing, use and disposal

Quality of life, working conditions,safety and health ofproduction equipment users

Competitiveness for Europeanmanufacturing industry, new ways ofmaking business

Attractiveness of manufacturingsector to all the society

OBJ 1

OBJ 2

OBJ 3

OBJ 4

Prod

ucti

on p

roce

sses

Sim

ulat

ion

Mon

itor

ing,

mea

sure

men

t

Ada

ptro

nics

New

mat

eria

ls

New

arc

hite

ctur

es

Con

trol

s

TECHNOLOGIES

THE GREEN MACHINES

THE MANUFACTURING FRONTIERS

ECONOMIC TRACK

RESEARCH ON KEY TECHNOLOGIES THAT WILL ALLOW BREAKTHROUGHS IN EACH TRACK (Keeping synergism between tracks)

INTEGRATED IMPLEMENTATION OF TRACK RESULTS INCORPORATING KEY TECHNOLOGIES INPROTOTYPES

SPECIFIC TRAININGACTIVITIES ON TRACKTOPICS. DISSEMINATION

OBJ 5

THE USER CENTRIC AUTONOMOUS MACHINES

DEM

ONST

RATO

RS:

Pro

toty

pes

and

new

way

s of

doi

ng

busi

nes

sBENEFITS FOR SMEsINDUSTRIES (Builders

and users of productionsystems) & EU

“NEXT GENERATION”PRODUCTION SYSTEMS

NEW

CO

NTEN

TS

FO

R T

RAIN

ING A

ND D

ISSE

MIN

ATIO

N

ARO

UND P

RO

DUCTIO

N E

QUIP

MEN

T

OVERVIEW OF NEXT PROJECT

NEXT IP 011815 5

CRITICAL MASS

MERGED 6 EXPRESSIONS OF INTEREST OF FP6

23 PARTNERS FROM 9 COUNTRIES

PARTNERS REPRESENT THE

COMPLETE “VALUE-CHAIN” FOR THE

EUROPEAN PRODUCTION

MACHINERY

MULTI-DISCIPLINARY TEAMS

ORGANISATION TYPE

FATRONIK Technology centre (E)

ASCAMM Industrial association (E)

BOSCH Industry – user (D)

BUTE University (HU)

CECIMO Industrial association (EU)

CESI Industry (I)

CNRS Research centre (F)

CR FIAT Industry – user (I)

DANOBAT Industry (E)

EPFL Universidad (CH)

FIDIA Industry (I)

HULLER HILLE Industry (D)

IFW HANNOVER University (D)

ISI Technology centre (D)

ITIA Research centre (I)

KU LEUVEN University (BE)

KUTXA Savings bank (E)

CORREA – ANAYAK Industry (E)

ONA Industry (E)

SIEMENS Industry (D)

TEKNIKER Technology centre (E)

WZL University (D)

EMCO Industry (A)

ASSOCIATIONSMANUFACTURERS

USERSTECHNOLOGY CENTRES

UNIVERSITIESFINANCIAL - KUTXA

CONSORTIUM

NEXT IP 011815 6

EXPECTED MACRO END RESULTS

TRACK1 THE GREEN MACHINES: Radical innovation forward environmentally friendly production machines.

DANOBAT DANOBAT Grinding machine

ONAONA EDM machine

TRACK1 THE GREEN MACHINES: Radical innovation forward environmentally friendly production machines.

DANOBAT DANOBAT Grinding machine

ONAONA EDM machine

TRACK2 THE USER CENTRIC AUTONOMOUS MACHINE: Breakthrough in usability and machine autonomy.

EMCO & CORREA EMCO & CORREA High speed milling machines

WZLWZL / BOSCH / BOSCH Gun drilling machine

TRACK2 THE USER CENTRIC AUTONOMOUS MACHINE: Breakthrough in usability and machine autonomy.

EMCO & CORREA EMCO & CORREA High speed milling machines

WZLWZL / BOSCH / BOSCH Gun drilling machine

TRACK3 THE MANUFACTURING BREAKTHROUGH: New processes due to a big leap performance and innovative processing methods.

FIDIAFIDIA High speed milling machine for dies and moulds

MAGMAG Agile machining centre for prismatic components

TRACK3 THE MANUFACTURING BREAKTHROUGH: New processes due to a big leap performance and innovative processing methods.

FIDIAFIDIA High speed milling machine for dies and moulds

MAGMAG Agile machining centre for prismatic components

NEXT IP 011815 7

TRACK4 NEW BUSINESS PARADIGM FOR MACHINERY: A breakthrough to create value for the production machinery business.

Methodologies for business model innovation

Business model life cycle evaluation software tool

Technical configurator

TRACK4 NEW BUSINESS PARADIGM FOR MACHINERY: A breakthrough to create value for the production machinery business.

Methodologies for business model innovation

Business model life cycle evaluation software tool

Technical configurator

TRACK5 NEW CONTENTS FOR TRAINING, MARKETING AND DISSEMINATION AROUND PRODUCTION EQUIPMENT.

Training methodologies and tools

Dissemination of results

TRACK5 NEW CONTENTS FOR TRAINING, MARKETING AND DISSEMINATION AROUND PRODUCTION EQUIPMENT.

Training methodologies and tools

Dissemination of results

EXPECTED MACRO END RESULTS

8

TRACK1: GREEN MACHINES

Radical innovation into environmentally friendly production machines. Consider environmental aspects through the entire life-cycle of machines: use of recycled materials for machine elements, reduction of energy consumption at machine use, zero waste produced, dismantling and recycling of 100% machines, and working in non-pollutant machining processes.

NEXT IP 011815 9

GRINDING Demonstrator EDD

EDD (Electro Discharge Dressing). Metallic bonded wheels dressed in the machine

BENEFITS Power consumption reduced up to 30% thanks to the increased

grain exposure in the wheel. Possibility to dress metallic superabrasive wheels in the own

machine with medium values of grain size more precision Lower piece cost because the life of the wheel is increased up to

40%. Tool life will be compared to machine life. Applications for hard metal grinding; any application of peeling

NEXT IP 011815 10

GRINDING Demonstrator MQL

MQL in grinding

BENEFITS Energy consumption reduced up to 50 %. Liquid power pumps are eliminated. Less space occupied by the machine, up to 50 % . Production costs reduced because the machine is

cheaper (less space needed) and power consumption reduced.

No liquid residues are produced

NEXT IP 011815 11

ONA Demonstrator (WEDM)

Development of high technological WEDM with better environmental behavior

INNOVATIONS Improve the Paper Cartridge filter lifetime

using a secondary filter washable module

Development of Washable filter suitable to treat higher amount of residues (high speed of 300 mm2/min possible)of WEDM machine with integrated high speed cutting generator.

Reduce the conductivity of the water dielectric fluid by flowing it through the resins interchange stage.• Resin consumption reduction

BENEFITS New filtration units will allow reducing the

waste generation up to 50%

NEXT IP 011815 12

DesignDesign

ManufactureManufacture

RecyclingRecycling

UseUse

Measure the power, tool and oil consumption

and the evaluating the noise and waste Develop a software tool for multi criteria

analysis for the design of new eco-efficient

processes and drive future improvements

GREEM SW TOOL Reduce the energy consumption of movable

machine and PKM robots components Machines: light weight materials Robots: choose the correct architecture;

use green materials like wood (light

weight, easier to recycle, needs low

energy request for the production)

Study the usage phase of the machine

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TRACK 2: USER-CENTRIC AUTONOMOUS MACHINE

Establishing the base of a new generation of autonomous and “user-friendly” machines that will support a much more efficient and comfortable way of working (e.g. automatic recognition of manufacturing tasks and process conditions).

NEXT IP 011815 14

EMCO E900 / CORREA

RELEVANT INNOVATIONS Automated identification of friction and

acceleration behaviour using trace functionality and Extended Trace Capability

Implementation of faster setup and calibration services

Integration of machine model within toolpath planning ( machining time up to 50%)

Implementation of an adaptive control that allows monitoring the surface roughness online

Implementation of a CUTOPT model-based surface roughness monitoring in milling operations

Implementation of an indirect thermal compensation

Implementation of a wear detection software for guide ways

Compensation

WZL

KU Leuven

NEXT IP 011815 15

EMCO E900 / CORREA

BENEFITS More reliable manufacturing

processes Higher accuracy of produced goods Reduction of reject rate Reduction of production costs Less maintenance services

Compensation

WZL

KU Leuven

NEXT IP 011815 16

Gun Drilling Demonstrator

Development & validation of 3D simulation models (Bosch, CRF, WZL)

Rotating actuator system for gun drilling (Nora, WZL)

Adaptive Control in gun drilling (Bosch, WZL)

Workpiece

Gundrill

INNOVATIONS Development and implementation of an adaptive control

system of the process to achieve an optimum performance

Development and implementation of a rotating actuator system for gun drilling

Development & validation of 3D FE simulation models Sep up of cutting simulation models for automotive

application machining

NEXT IP 011815 17

Gun Drilling Demonstrator

BENEFITS The use of an adaptive control in gun drilling allows increasing the

productivity and the process reliability. As process behavior changes significantly during manufacturing, and

adaptation of controller parameters is essential to achieve the optimum in performance. The objective is to machine at the tool’s load limit.

For Bosch large scale injector pipe manufacturing is the main field of application while CRF is mainly interested in drilling crankshafts

The simulation contributes a quick analysis of tool load limits whithout raising test costs.

The availability of production machines increases as initial tool tests can be reduced or generally avoided.

18

TRACK 3: THE MANUFACTURING BREAKTHROUGH

Designing and building the best process-controlled production machines in the world in terms of performance, productivity and achievable quality (2x - 5x improvement in machine tool productivity, increasing accuracy, higher reliability).

NEXT IP 011815 19

High Speed Milling Machine for dies&moulds machining – FIDIA

NEXT IP 011815 20

High Speed Milling Machine for dies&moulds machining – FIDIA

BENEFITS Improvement in productivity of about 10% is the target related to the

implementation of knowledge and process-related algorithms in an open architecture framework , contributing with a 4% revenue increment in selling CNC (over 300.000 € in two years)

Improvement in performance of about 10-15% by using light weight ram (Al-foam, CFRP) with a ram cost increase of 30% (2.000 € against 1.500 €)

Improvement in performance of about 20% by implementing a thermal compensation system based on FBG’s with a ram cost increase of 50% (fibers + reading unit) (machine cost increase of 5-7%)

The implementation of innovative and easy-to-apply methods will allow for performing ECO-impact analysis on machine tools with time and costs which are suitable and tailored to such application

NEXT IP 011815 2121

Agile Machining Centre for Prismatic Components - MAG

INNOVATIONS Modular design: Configurability of wide

range of machine variants by using a smaller number of common modules and components

Model based temperature compensation in order to avoid the loss of accuracy caused by thermal influences

Compile cycles for advanced control in order to get exact and fast positioning of heavy mass

Set-up and calibration service in order to decrease the setup time of a 5 axis machine

Energy saving program Optimization of high performance cutting

NEXT IP 011815 2222

Agile Machining Centre for Prismatic Components - MAG

BENEFITS Reduced investment costs Reduced warm up time and increased accuracy Faster and more exact positioning Faster set-up time Increase material removal rate

23

TRACK 4: Economic objective

New ways of doing business in the production machinery sector. Exploring and defining new ways of selling products AND services, new formulae not currently applied related to ownership of the equipment, payment, financing, new organisation models, etc..

NEXT IP 011815 24

New business models

Technical Configurator

Business Modelevaluation life cyclesoftware

Technical Guidelines

Methodology to selectCooperation Scenarios

Financial Guidelines

OrganizionalGuidelines

Technical Configurator

Business Modelevaluation life cyclesoftware

Technical Guidelines

Methodology to selectCooperation Scenarios

Financial Guidelines

OrganizionalGuidelines

NEXT IP 011815 25

New business models

INNOVATIONS Consultancy methods, contents and tool for

business model innovation of manufacturing companies

Business model life cycle assesment software Technical configurator

NEXT IP 011815 26

New business models

BENEFITS Consultancy methods, contents and tool for

business model innovation of manufacturing companies They enable high-level consulting in the fields of customer-

oriented business model selection and in adapting organizational structures to the newly arising requirements will be offered to machine tool building companies

Clear and structured methodology for strategic innovation Decision support systems to assist strategic decisions:

a)Cooperation scenarios preliminary selector; b) Financial guidelines; c) Organizational guidelines

NEXT IP 011815 27

New business models

BENEFITS Business model life cycle assesment software

Evaluation of the economical and environmental performances deriving from the adoption of an innovative business model with respect to the actual one. It permits to quantitatively evaluate the impact of innovative cooperation options between supplier and customer/business partners and of unconventional financial models.

Focus not only on machine tool, but on the whole production system

Customer/supplier win-win situations for the competitiveness of the whole manufacturing system and not only of some of its actors

NEXT IP 011815 28

New business models

BENEFITS Technical configurator

Supports the search, selection and configuration of machine tools and manufacturing systems, calculates system attributes (e.g. cost, space occupation, MTBF, MTTR) needed by LCA, and visualizes the 3D models of the configured machinery.

Allows more efficiency in offers preparation, a higher probability of their success,and a professional technical-commercial approach that will attract customers.

Customers will be more involved during the definition of the manufacturing system that should fulfill their industrial need. They will have the opportunity to consider technical aspects in advance and to make a better choice. More than one technical alternatives will be configured and evaluated, so that the guarantee that the system will be effective will be higher.