Based on feedback from the end users involved in Twin-Control, the requirements of the projects were determined in detail. After this preliminary work, technical developments were carried out to obtain different features that have been integrated in three main exploitable results of the project.
A new approach to simulate machining processes has been developed based in SAMCEF Mecano FEM solver. A digital representation of machine tools can be developed in this environment by combining structural FEM analysis, specific elements for the feed drives and control loop models. The novelty of this approach consists in the integration of new machining process models that provides the chance to evaluate machine tool performance during manufacturing operations. For process-specific analysis, these models are also available in standalone mode to provide a fast and easy simulation tool. The loads estimated by this integrated simulation can be used by additional modules simulating life cycle performance of the machines.
An advanced local monitoring and control system has been developed, based in ARTIS hardware and integrating new features developed by Twin-Control partners. ARTIS Genior Modular can connect to machine CNC/PLC and get internal signals at a high sample rate. Apart from the complete monitoring capabilities, this system has enhanced features:
- Process monitoring: after a learning stage of a specific process, process related thresholds are defined for all monitored signals that allow detecting anomalous performance. The integration of the new process models developed in Twin-Control will allow the determination of these thresholds without the need of a learning stage.
- Adaptive feedrate control: According to a defined spindle consumption setpoint, the system can adapt machine tool feedrate to increase productivity.
- Component-level energy monitoring: a low-cost energy monitoring concept is proposed, based on the disaggregation of the machine’s total power consumption.
- Collision Avoidance System: a graphical simulation environment that uses real positions of the machine, and I able to predict collisions and stop the machine in advance.
A cloud-based fleet-wide platform for machine tool condition, performance analysis and proactive maintenance has been developed. The KASEM® platform, provides an easy-to-use interface, allowing creation of algorithms and visualization of the evolution of indicators or the generated reports. The solution provides:
- More than 60 KPIs for the health status of machine-tool and its sub-systems
- An accurate and dynamic diagnostic tool thanks to a root-cause analysis and modelling of physics
- Additional indicators obtained by the implementation of the Quick Machine Tool Characterization tests developed in Twin-Control
- Integration of Remaining Useful Life (RUL) calculation of critical components.
In the last year of the project, the different developments have been evaluated in two industrial validation scenarios: aerospace and automotive. The evaluation served to validate the presented features, apply them in an industrial environment and evaluate the impact on end users.
A complete exploitation plan (business model, market and risk analysis) has been defined for the three main results of the project. For each result an exploitation leader has been defined to finalize the work to make these results ready for market.
Twin-Control activities have been disseminated to different audience. The website (
http://twincontrol.eu/(se abrirá en una nueva ventana)) and twitter account (@Twin_Control) have been providing updated information about project status and relevant events to the general public. Project developments have been also presented in industrial forums, like machine tool fairs, and specific workshops have been organized in relevant pilot lines by project partners. Regarding scientific dissemination, apart from presentations of project results in several international conferences, a book compiling project activity will be published.
