Periodic Reporting for period 2 - Mari4_YARD (User-centric solutions for a flexible and modular manufacturing in small and medium-sized shipyards)
Berichtszeitraum: 2022-06-01 bis 2023-11-30
Mari4_YARD focuses on increasing the efficiency in the construction of complex vessels by small and medium-sized shipyards. It will be reached through the implementation of a comprehensive automation adoption based on worker-centric tools comprising a set of a modular, portable and more flexible equipment. Mari4_YARD implements novel robotics and ubiquitous portable solutions targeting the execution of labour-intensive tasks in steelwork, pre-production and outfitting stages for both novel construction and retrofitting/repairing, by preserving industry-specific workers’ knowledge and skills.
The solutions will be implemented, benchmarked and demonstrated in real-scale demonstrators, for novel ship construction and retrofitting/repairing. In addition, a pan-European network of Didactic Factories will be established, easing the access to the developed technologies to a broad basis of EU shipyards and manufacturing companies.
The technical approach will be supported by safe, modular and collaborative robot solutions with skill-based and intuitive robot programming to improve production; AR/MR tools, video projection as well as superimposing CAD information, for a precise positioning of the different subassemblies; Use of exoskeletons to reduce the workers physical effort in the execution of the target tasks; The implementation of 2 real-scale demonstrators in small and medium-sized shipyards; Stablishing a Didactic Factories Networks with five pilot lines enabling EU-wide workforce upskilling and technology adoption by EU industry, ensuring a successful market uptake.
Mari4_YARD will push to create the Mari4 alliance community to promote the business around the portfolio of user-centric solutions under development.
The solutions will be implemented, benchmarked and demonstrated in real-scale demonstrators, for novel ship construction and retrofitting/repairing. In addition, a pan-European network of Didactic Factories will be established, easing the access to the developed technologies to a broad basis of EU shipyards and manufacturing companies.
The technical approach will be supported by safe, modular and collaborative robot solutions with skill-based and intuitive robot programming to improve production; AR/MR tools, video projection as well as superimposing CAD information, for a precise positioning of the different subassemblies; Use of exoskeletons to reduce the workers physical effort in the execution of the target tasks; The implementation of 2 real-scale demonstrators in small and medium-sized shipyards; Stablishing a Didactic Factories Networks with five pilot lines enabling EU-wide workforce upskilling and technology adoption by EU industry, ensuring a successful market uptake.
Mari4_YARD will push to create the Mari4 alliance community to promote the business around the portfolio of user-centric solutions under development.
During the first stages of the project different processes were identified and analysed as potential use-cases for the deployment of the user-centric tools, obtaining a relation of application cases and technologies with the potential to impact the current processes improving any of the analysed KPIs (Safety, Time, Process Control, Quality, Ergonomics, Cost). Considering the analysed processes, 3 testbenches to be used in the development and demonstration stages were designed and installed at AIMEN facilities.
In this 2nd period, the technology development phase of the portfolio of technologies was finalized and validated in the Didactic Factories and defined testing sprints, conducted based on the iterative design and development for all the portfolio of technologies (Catalogue of the Mari4_YARD solutions - Mari4_YARD (mari4yard.eu)). Performance indicators and the demonstrator scenarios were selected. Internal training was designed and conducted.
Aerial surveillance technology for shipyard production planning, a web-based platform was established for logistics planning tasks and reverse engineering tests were conducted with a drone-mounted LIDAR. Ensured interoperability of user-centric tools by developing a methodology to exchange related 3D data in STEP format, suggesting OPC-UA protocol to connect robot information to digital infrastructure.
Robotic validations for a new gripping device, its deployment with high-payload robots in shared spaces, and the operation of small collaborative robots in ship blocks were successfully completed. A multi-layered safety system, initially designed, now enables SSM (Speed and Separation Monitoring), SRS (Safety Rated Stop), and HG (Hand Guiding) operational modes as defined in the ISO/TS 15066. To ensure robot autonomy, we've implemented a set of modular perception solutions using cost-effective sensing devices for the proposed application cases. The completion of the control orchestration and planning module was achieved, incorporating human-centric tools for intuitive interfaces. Additionally, an Intuitive Human-robot collaborative solution was developed, leading to a human-robot interaction suite with technologies like force control and augmented reality.
Augmented Reality and Mixed Reality solutions were developed using Tablet devices, headsets and projectors to help the workers in different manufacturing stages. Tablets and Headsets are being used for construction supervisions and training, introducing a 3D step-by-step workflow approach, while projectors are intended to give direct support manufacturing operations in outfitting stage, incorporating a motorized pan/tilt unit allowing the execution of localization and projection algorithms.
Exoskeletons have already been deployed in both the testing facilities and at end-user facilities to check technical aspects before entering the fabrication stage of the two novel independent solutions created in the Mari4_YARD initiative, developing a lightweight, semi-active spring-loaded exoskeleton for shoulder and lumbar flexion support, creating an AI-based algorithm for user effort recognition, and developing process perception technology using AI techniques.
The deployment phase has started focused on the demonstration setup for Mari4_YARD technologies at the end-user facilities, defining the scenarios and performance indicators, with an emphasis on business and technology requirements.
Advances were also made in other transversal tasks, as sustainability, communication and exploitation activities.
In this 2nd period, the technology development phase of the portfolio of technologies was finalized and validated in the Didactic Factories and defined testing sprints, conducted based on the iterative design and development for all the portfolio of technologies (Catalogue of the Mari4_YARD solutions - Mari4_YARD (mari4yard.eu)). Performance indicators and the demonstrator scenarios were selected. Internal training was designed and conducted.
Aerial surveillance technology for shipyard production planning, a web-based platform was established for logistics planning tasks and reverse engineering tests were conducted with a drone-mounted LIDAR. Ensured interoperability of user-centric tools by developing a methodology to exchange related 3D data in STEP format, suggesting OPC-UA protocol to connect robot information to digital infrastructure.
Robotic validations for a new gripping device, its deployment with high-payload robots in shared spaces, and the operation of small collaborative robots in ship blocks were successfully completed. A multi-layered safety system, initially designed, now enables SSM (Speed and Separation Monitoring), SRS (Safety Rated Stop), and HG (Hand Guiding) operational modes as defined in the ISO/TS 15066. To ensure robot autonomy, we've implemented a set of modular perception solutions using cost-effective sensing devices for the proposed application cases. The completion of the control orchestration and planning module was achieved, incorporating human-centric tools for intuitive interfaces. Additionally, an Intuitive Human-robot collaborative solution was developed, leading to a human-robot interaction suite with technologies like force control and augmented reality.
Augmented Reality and Mixed Reality solutions were developed using Tablet devices, headsets and projectors to help the workers in different manufacturing stages. Tablets and Headsets are being used for construction supervisions and training, introducing a 3D step-by-step workflow approach, while projectors are intended to give direct support manufacturing operations in outfitting stage, incorporating a motorized pan/tilt unit allowing the execution of localization and projection algorithms.
Exoskeletons have already been deployed in both the testing facilities and at end-user facilities to check technical aspects before entering the fabrication stage of the two novel independent solutions created in the Mari4_YARD initiative, developing a lightweight, semi-active spring-loaded exoskeleton for shoulder and lumbar flexion support, creating an AI-based algorithm for user effort recognition, and developing process perception technology using AI techniques.
The deployment phase has started focused on the demonstration setup for Mari4_YARD technologies at the end-user facilities, defining the scenarios and performance indicators, with an emphasis on business and technology requirements.
Advances were also made in other transversal tasks, as sustainability, communication and exploitation activities.
The lack of a standard 3D data formats difficult the interoperability in shipbuilding sectors, effort needed how to keep all the metadata and make it compatible for all the user-centric tools, especially the AR/VR solutions and define the digital infrastructure for process data handling in shipyards with a low degree of digitalization. In the 3D scanning side, the main challenge is related to the deployment of robots inside the vessels. Also challenging the stitching of point clouds using dynamic acquisition, as the GPS localisation available in the drone is not precise enough when deployed inside closed areas.
Deploying robots in shared spaces presents a major challenge: developing new tech solutions to enhance fabrication processes and ensure worker safety. Defining easily certifiable safety systems is crucial. These systems enable testing proposed solutions at end-user facilities without safety restrictions, allowing the potential impact of user-centric tools to increase. Perception is vital, necessitating adaptation of consortium-developed perception technologies based on cost-effective sensing devices. Further software development is needed to achieve reasonable results, which could otherwise be obtained with current market solutions at higher costs.
Designing exoskeletons to meet shipbuilding environmental requirements is a significant step change. Exoskeletons were initially for general industry sectors, but their design fails to meet specific environmental needs. Identifying these needs and redesigning exoskeletons accordingly is the primary challenge, with usability being the second. As most market exoskeletons are passive, designing battery-powered exoskeletons with control boards for actuators and sensors is crucial.
Deploying robots in shared spaces presents a major challenge: developing new tech solutions to enhance fabrication processes and ensure worker safety. Defining easily certifiable safety systems is crucial. These systems enable testing proposed solutions at end-user facilities without safety restrictions, allowing the potential impact of user-centric tools to increase. Perception is vital, necessitating adaptation of consortium-developed perception technologies based on cost-effective sensing devices. Further software development is needed to achieve reasonable results, which could otherwise be obtained with current market solutions at higher costs.
Designing exoskeletons to meet shipbuilding environmental requirements is a significant step change. Exoskeletons were initially for general industry sectors, but their design fails to meet specific environmental needs. Identifying these needs and redesigning exoskeletons accordingly is the primary challenge, with usability being the second. As most market exoskeletons are passive, designing battery-powered exoskeletons with control boards for actuators and sensors is crucial.