Automating what is not automatable Automated defect diagnosis and Machining system for manufactured parts.

Description du projet

Automatiser les contrôles de l’usinage des métaux

L’automatisation au niveau de l’atelier est essentielle, en particulier pour le tournage, le fraisage et la rectification des pièces, afin de réduire les temps de cycle et d’améliorer la qualité. Mais les processus d’inspection qui impliquent des opérateurs humains utilisant des logiciels et des équipements pour vérifier la qualité et les dimensions restent peu automatisés. Or, il s’agit d’une étape consommatrice de temps qui implique la mesure de la pièce fabriquée, la comparaison avec la géométrie requise et l’usinage. Le projet SCR4.0 financé par l’UE, entend accélérer ce procédé. Il permettra en effet d’automatiser le contrôle de qualité final et le processus d’usinage. Selon le projet, l’automatisation de l’ensemble du dispositif dans une cellule de fabrication intégrée intelligente permettra d’augmenter la productivité (jusqu’à 33 %) et de réduire les coûts (jusqu’à 50 %) au cours des trois premières années.

Objectif

ASAI is a Spanish SME bringing quality industrial automation to our clients in the automotive and other diverse industries. We have broad technical knowledge in scanning, robotics, software and automation and strong, management, industry knowledge, and supplier links for completion of the SCAN-CAM-ROBOT 4.0 (SCR4.0) project.
Our aim with the SCR4.0 is complete automation of the final quality control and machining process. The current process requires measurement of the manufactured part, comparison with required geometry and machining of the part. 3 separate activities linked by human operators using software and equipment. These solutions are slow, costly, and inefficient. For example, in the aluminium injection casting industry machining costs are 20 to 50% of average completed part and cause time delays of up to 75% for a part and material wastage of up to 15%.
The SCR4.0 will automate the entire process, in one smart integrated manufacturing cell that is compatible with Industry 4.0 for full factory and supply chain automation. Leading to Increased productivity (up to 33%) and lower costs (up to 50%) in just the first 3 years including payoff. Selective machining by the SCR4.0 will be possible by inline 3D scanning of all parts achieves extra energy and material savings (up to 20%).
Industry 4.0 (factories of the future) is growing, expected to reach €139 Billion by 2024. Our target material, Aluminium, is increasing in the automotive industry for light-weighting for emissions reduction, expected to reach 20% of material by 2026; with an increase in required complex machining for mechanical parts. Metal injection moulding (our customers primary activity) is to grow from €2.3 Billion in 2017 to € 3.35 Billion by 2022.
With an additional €2.3M investment, we can bring the SCR4.0 to this growing market through our global customer network and new links with aluminium parts manufacturers. Given the demonstrated savings they will be keen to implement the SCR4.0.