Periodic Reporting for period 3 - CHARM (Challenging environments tolerant Smart systems for IoT and AI)
Reporting period: 2022-06-01 to 2024-02-29
Digitalization has been identified as one of the key enablers for renewal and competitiveness of European manufacturing industries. Harsh environmental conditions of the manufacturing processes and user environments are a severe challenge tackled by the ECSEL-IA 2019 project initiative CHARM, by developing sensor solutions to tolerate the conditions. The project solves real industrial challenges for reliable real-time monitoring of manufacturing processes, precision measurement and maintenance. The synergies and impacts come from similarities in the technology solutions of sensing and cloud connectivity for the different applications.
CHARM includes use cases represented by innovative enterprises which are market leaders in their own fields: mining (Sandvik Mining and Construction, FI), paper mills (Valmet Technologies, FI), precision measurements (Sylvac, CH), solar panel manufacturing lines (Applied Materials Italia, IT), nuclear power plant maintenance (ÚJV Řež, CZ), and professional digital printing (Canon Production Printing Netherlands, NL). The technologies developed include novel multi-gas sensors, robust high temperature sensors, sensors and wireless power transfer systems for paper machine rotating suction rolls, advanced vision system for temperature measurement in drying ovens, and a robust highly miniaturized data processing unit with capability to operate in autonomous underground mining vehicles. Beyond the state-of-the-art packaging technologies have been developed and the use case solution functionalities demonstrated.
The project consortium includes 11 SMEs, 14 LEs and 12 RTOs, and covers the industrial value chain from simulations, sensor development and component packaging, integration and reliability as well as connectivity, cloud and cyber security solutions.
The activities go beyond the state of the art, contributing to the competitiveness and leadership of European industry and ECS competences, providing new business opportunities for the partners and their supplier ecosystem. New digitalization capabilities and cybersecurity options for industrial environments have been developed.
CHARM includes use cases represented by innovative enterprises which are market leaders in their own fields: mining (Sandvik Mining and Construction, FI), paper mills (Valmet Technologies, FI), precision measurements (Sylvac, CH), solar panel manufacturing lines (Applied Materials Italia, IT), nuclear power plant maintenance (ÚJV Řež, CZ), and professional digital printing (Canon Production Printing Netherlands, NL). The technologies developed include novel multi-gas sensors, robust high temperature sensors, sensors and wireless power transfer systems for paper machine rotating suction rolls, advanced vision system for temperature measurement in drying ovens, and a robust highly miniaturized data processing unit with capability to operate in autonomous underground mining vehicles. Beyond the state-of-the-art packaging technologies have been developed and the use case solution functionalities demonstrated.
The project consortium includes 11 SMEs, 14 LEs and 12 RTOs, and covers the industrial value chain from simulations, sensor development and component packaging, integration and reliability as well as connectivity, cloud and cyber security solutions.
The activities go beyond the state of the art, contributing to the competitiveness and leadership of European industry and ECS competences, providing new business opportunities for the partners and their supplier ecosystem. New digitalization capabilities and cybersecurity options for industrial environments have been developed.
Efforts in risk management and replanning were made for the unforeseen COVID-19 pandemic and global component shortages during the first 24 months. A 9-month extension period had to be planned to meet the planned objectives. The main results include:
UC1: IOT for digital mining solutions: air quality & autonomy in mining vehicles
Project has produced lot of information on how to build air quality sensing. Testing is lacking due to delays in component delivery. Accurate air quality sensing would enable on demand ventilation and save energy costs, but solutions do not exist. Ventilation is the single biggest operating energy expense in mining operations.
Market development on environment sensing technologies has been faster than anticipated at the project start. LIDAR, stereo cameras, image streaming and such technologies outperform the set targets. Radars will be part of future automation technologies, but their role is still unclear.
UC2: Condition monitoring of paper mill equipment
The project has enabled capability and knowledge for condition monitoring of paper machines. Sensors (temperature, wear, vibration, oil condition, angle position), hardware configurations applicable for industrial installations, SW for real-time measurement and data collection, capability for local connectivity, and remote configuration.
UC3: Real-time machining workpiece control system
A linear motion scanning system for simulating the environment (oil and machined chips) has been developed to measure oily parts without the need for cleaning or thermal stabilization. The system strengthens Sylvac position as a technological leader in dimensional metrology.
UC4: Real time monitoring of solar panel manufacturing lines
Novel temperature sensors in drying ovens for solar cell manufacturing lines have been developed. This improves process control in PV screen printing: higher uptime, yield, and performance of the final product, savings in paste, utility and operator costs. New opportunities open in high performances solar cells, such as IBC heterojunction, TOPCon, Perovskite.
UC5: Nuclear plant maintenance and decommissioning
A new in-service inspection robot with advanced robot trajectory planning and a new control user interface has been developed and tested. It enables UJV Rez to improve advanced robotic in-service inspection and maintenance of nuclear power plants.
UC6: Virtual prototyping professional digital printers
Virtual printer sensors have been developed for evaluating image quality improvements, such as graininess, and color gamut, and for evaluating the print robustness, such as ink wrinkle. The outcome enables CPP to release innovative printer products earlier to the market, increase sales and market share.
• Partners have contributed to >130 international conferences, trade shows, workshops and events.
• 6 peer reviewed open access articles and 8 additional non-open articles are published.
• 4 patent applications have been filed. New, unforeseen, ideas have been reported by almost all partners.
• Appx. 200 social media, website and other press releases are published.
• >60 CHARM LinkedIn posts have been published, and many more by partners.
UC1: IOT for digital mining solutions: air quality & autonomy in mining vehicles
Project has produced lot of information on how to build air quality sensing. Testing is lacking due to delays in component delivery. Accurate air quality sensing would enable on demand ventilation and save energy costs, but solutions do not exist. Ventilation is the single biggest operating energy expense in mining operations.
Market development on environment sensing technologies has been faster than anticipated at the project start. LIDAR, stereo cameras, image streaming and such technologies outperform the set targets. Radars will be part of future automation technologies, but their role is still unclear.
UC2: Condition monitoring of paper mill equipment
The project has enabled capability and knowledge for condition monitoring of paper machines. Sensors (temperature, wear, vibration, oil condition, angle position), hardware configurations applicable for industrial installations, SW for real-time measurement and data collection, capability for local connectivity, and remote configuration.
UC3: Real-time machining workpiece control system
A linear motion scanning system for simulating the environment (oil and machined chips) has been developed to measure oily parts without the need for cleaning or thermal stabilization. The system strengthens Sylvac position as a technological leader in dimensional metrology.
UC4: Real time monitoring of solar panel manufacturing lines
Novel temperature sensors in drying ovens for solar cell manufacturing lines have been developed. This improves process control in PV screen printing: higher uptime, yield, and performance of the final product, savings in paste, utility and operator costs. New opportunities open in high performances solar cells, such as IBC heterojunction, TOPCon, Perovskite.
UC5: Nuclear plant maintenance and decommissioning
A new in-service inspection robot with advanced robot trajectory planning and a new control user interface has been developed and tested. It enables UJV Rez to improve advanced robotic in-service inspection and maintenance of nuclear power plants.
UC6: Virtual prototyping professional digital printers
Virtual printer sensors have been developed for evaluating image quality improvements, such as graininess, and color gamut, and for evaluating the print robustness, such as ink wrinkle. The outcome enables CPP to release innovative printer products earlier to the market, increase sales and market share.
• Partners have contributed to >130 international conferences, trade shows, workshops and events.
• 6 peer reviewed open access articles and 8 additional non-open articles are published.
• 4 patent applications have been filed. New, unforeseen, ideas have been reported by almost all partners.
• Appx. 200 social media, website and other press releases are published.
• >60 CHARM LinkedIn posts have been published, and many more by partners.
New business in remote paper mill condition monitoring applications and services for Valmet. The first customer use cases and installations were identified in 2023.
Linear motion scanning simulation environment key gains will reduce machine setup time 50%, reduce cleaning and stabilization times, and hence cost savings. Sylvac sees opportunities for +30% more sales, and up to 10% increase in market share. Customer environmental impacts are lower use of cleaning agents and promoting sustainable machining practices.
Applied Materials Italia sees potential for the applications of the temperature sensors for drying ovens to allow drying process optimization after screen-printing. The technology and competences strengthen the European solar equipment manufacturers and opens new job opportunities for skilled professionals.
The CHARM outcomes will transform UJV Rez's operations and position the company as a leader in affordable nuclear plant maintenance and in-service inspection. OEM competitors do not provide similar equipment or inspection services. Beyond SotA achievements include robot weight and footprint reduction by up to 80%, inspection velocity increase by up to 400 %, repeatability improvement up to 80%, and end-effector vibration attenuation reduction by up to 80%.
The CHARM outcomes have contributed to new releases in the VarioPrint and Colorado products and improved the development efficiency of Canon globally, one of the few European based professional digital printer manufacturers. The project outcomes Allows to run more experiments to determine and validate designs while building less prototypes. This allows reduction in development time, product cost, and development resources, by 10-15%, 2-5%, and 5-10%, respectively.
SSH has introduced the PrivX OT Edition, a new product tailored to the Operational Technology market providing secure communication and access management for IoT devices. Initial customer cases have been secured, demonstrating the demand for the solution.
Linear motion scanning simulation environment key gains will reduce machine setup time 50%, reduce cleaning and stabilization times, and hence cost savings. Sylvac sees opportunities for +30% more sales, and up to 10% increase in market share. Customer environmental impacts are lower use of cleaning agents and promoting sustainable machining practices.
Applied Materials Italia sees potential for the applications of the temperature sensors for drying ovens to allow drying process optimization after screen-printing. The technology and competences strengthen the European solar equipment manufacturers and opens new job opportunities for skilled professionals.
The CHARM outcomes will transform UJV Rez's operations and position the company as a leader in affordable nuclear plant maintenance and in-service inspection. OEM competitors do not provide similar equipment or inspection services. Beyond SotA achievements include robot weight and footprint reduction by up to 80%, inspection velocity increase by up to 400 %, repeatability improvement up to 80%, and end-effector vibration attenuation reduction by up to 80%.
The CHARM outcomes have contributed to new releases in the VarioPrint and Colorado products and improved the development efficiency of Canon globally, one of the few European based professional digital printer manufacturers. The project outcomes Allows to run more experiments to determine and validate designs while building less prototypes. This allows reduction in development time, product cost, and development resources, by 10-15%, 2-5%, and 5-10%, respectively.
SSH has introduced the PrivX OT Edition, a new product tailored to the Operational Technology market providing secure communication and access management for IoT devices. Initial customer cases have been secured, demonstrating the demand for the solution.