Innovative Laser Solution for Cutting Welding TWIP steel with IMProved Performance

Project Information

TWIMP

Grant agreement ID: 696747

DOI

10.3030/696747

Project closed

EC signature date 23 October 2015

Start date 1 November 2015

End date 31 October 2017

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 2 704 073,75

EU contribution

€ 1 892 851,63

Coordinated by

ELETTROSYSTEM SRL
Italy

Periodic Reporting for period 2 - TWIMP (Innovative Laser Solution for Cutting Welding TWIP steel with IMProved Performance)

Reporting period: 2016-11-01 to 2017-10-31

Summary of the context and overall objectives of the project

TWIMP is an innovative, stand-alone laser machine applicable for cutting and welding processes, with following added value.

• Special steels processability (TWIP, DP600 and other AHSS steels), including standard steels as well.
• Compact dimension (< 10 m2 used area).
• Cheaper shipping costs and reduced installation time.
• Easy to use and fast to program (ISO G code programming mode same as machinery) but including in the meantime advanced programming mode for high-end applications.
• Flexible to operate in standalone or integrated mode with semi-automatic or full automatic environment.
• Modular and Scalable platform: machine can grow with customer business growth.
• From prototyping solution to mass production processes.

TWIMP machine can process complex shape components in the material TWIP (Twinning Induced Plasticity Steel, belonging in the Advanced High Strength Steels).
These components, made of TWIP steel, are generally applied in the Automotive Industry, where there is an urgent need of weight reduction and safety improvement of vehicles. TWIP steel, being stronger and lighter than conventional metals, is the perfect solution to this problem, and the TWIMP machine has been developed to provide a compact machine, for cutting and welding of these new materials, to automotive component manufacturers according to the extremely high standards.

TWIMP machine is faster and cheapest than comparable MIG welding machines in terms of minor power consumption and process cost; some important advantages are given by the absence of filling material and the adoption of process controls to limit steel structure deviation during welding. Another important advantage of TWIMP machine is the small footprint, and its competitive cost (compared with other manufacturers of laser welding equipment), TWIMP machine will be an invaluable addition to the industry. In fact, its reduced dimensions and monolithic structure allow quick and cheap shipping, optimized installation time/cost and low footprint usage in customer facilities.
Platform is modular and ready for horizontal stacking of multiple TWIMP machines in order to perform complex processes and/or inline integration. TWIMP machine can be used in stand-alone applications, with manual loading/unloading process, up to full automatic processes.

TWIMP programming language and Human Machine Interface are very common in machinery environment, furthermore machine collects advanced programming mode (Motion control, Robotic Control, Ladder, C++, Structured) in a unique platform which makes available an high-end, adaptive machine to a very wide range of engineering applications.

TWIMP has created a new disruptive machine that change the paradigm for the cutting and welding application and performance of process itself, increasing productivity, reducing costs for process and overall with under a simplified environment with right approach to a global market.

Furthermore, the integration of TWIMP machine in a cloud based environment, make it ready for Industry 4.0 application and big data collection from machine installed in the future, will help to improve performance and service to final customer with higher quality service and production performances.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During TWIMP project development, 24 months, the following milestones were achieved:
• Miniaturization of machine
• Tool adaptation to cut and weld complex shapes.
• Process control system optimization.
• User Friendly interface development.
• Manufacturing of prototype and industrial demonstration.
• Dissemination and commercialization activities.

Miniaturization of machine developed in WP1 Task 1.1 was done and deliverable was produced to report the results. TWIMP machine is now very compact, with less than 10 m² of footprint but we went ahead.
Tool adaptation, developed in WP1 Task 1.2 is another won challenge. ES team not pursued only the result but also the best quality. This solution has been achieved with research, and evaluation of commercial components and customizing mechanical fixture so that different parts are moved according to interpolating movements of robotized arm. The right mix of commercial devices, mechanical solutions and software development are the ingredients of a machine able to cut and weld 3D articulated shapes also with a gap among the edges.

Development of process control system, done in WP2 Task 2.1 2.2 integrated in a new user-friendly interface, developed in WP3 Task 1.1 and 2.2 opened a new scenario for TWIMP machine application and commercialization, because It reduces the distance between a complex machine and process and low level skilled people in production environment. ES team worked on WP2 and WP3 with focus to obtain a simply usage of a complex machine, thinking on the point of view of the final customer that needs to deploy a complex process but with a simple and fast procedure.

This solution makes accessible a complex environment to customers who doesn’t needs knowledge of robotics, software and so on and during the dissemination activities this is one of the most appreciated characteristics of TWIMP machine from potential customers.
Prototype realized in WP4 is a complete success in order to validate and confirm the potential of TWIMP machine, confirming proof of principles and demonstrate to project aim but also market needs, that TWIMP machine can solve many processes not yet defined in the market by other competitors.

Dissemination and commercialization activities, carried on during WP5 Task 5.2 was focused on reaching of different markets all around the world, with support of OTF of EC and independently with participation to B2B meeting, workshops, trade fair and direct contact of potential customers. Moreover, some new scenarios were opened on potential fields and markets for TWIMP machine, facing some new request from electronic and biomedical sectors, to weld and cut many different materials like aluminum, magnesium.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The pragmatic approach gives to TWIMP project a higher development level, merging successfully an R&D project to market requests with great results under technical and commercial point of view, because Elettrosystem already sold first two TWIMP machines to new customers.
Elettrosystem expects a big impact in terms of technology advantage and market demand because the first dissemination activities, B2B meetings and marketing events, returned a very high interest: in consideration of the initial progression of the TWIMP project, this is a very good result.

TWIMP machine features together with twip steel performance opens a totally new scenario of parts production for automotive industry and many other fields.
The need of strength, safety, reliability, and low carbon emission are pushing most of car maker brands to new materials and technology applications; light weight steels give an answer to this need and over automotive field, many other sectors/industries need the same.
Before TWIMP machine, no other technologies made possible twip steel junction, with different thickness, without filling material, and without steel characteristic deviation and this means only one thing: new process and new solution may be studied and adopted to produce new lighter and safe vehicles.

This is a very disruptive impact for car makers, drivers and environment, making vehicles safer with less energy consumption and low CO2 emissions.

Beta 1 Design

Final TWIMP Prototype manufactured 03

Final TWIMP Prototype manufactured 01

Final TWIMP Prototype manufactured 02

Beta 2 Design