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Intelligent monitoring, diagnostics and maintenance system in flexible production

Deliverables

The methodology contains a vast amount of knowledge about methods and rules for structuring of models from a new plant, integration rules for set-up of INTELL-DIAG Tools as for example the machine interfaces, methods for set-up of reasoning methods and their restrictions. The methodology represents the guideline for the services which can be applied to further plants to accelerate the integration of reasoning tools immensely so that set-up of infrastructure, interfaces, reasoning tools and knowledge repositories would not waste too much time and will improve the acceptance of users by tailored and sophisticated tools and data bases. The resulting experience of the partners filled into the INTELL-DIAG Methodology is of extraordinary importance for further services in the diagnosis area. On the market there is still a big vacuum for diagnostic systems, which can cope with complex and competitive industrial plants. So a successful product as INTELL-DIAG is planned to be has an immense potential on the market. Of course concurrently to sale of the product the demand for the methodology is immense, too. Consequently the exploitation of the methodology is regarded as very fruitful. Potential applications: The main application domain is in complex highly automated manufacturing systems, such as automotive industry (see for both INTELL-DIAG Tools). End-users: The INTELL-DIAG Products will be first offered to the automotive sector since the large end-user in the consortium (DaimlerChrysler) comes from this sector and tools will be first applied at their plants. The next potential market segment are suppliers of the automotive industry as ALUTECH is. A distinction must be made between large supplier and SMEs in this sector. The third potential segment for the INTELL-DIAG Tools will be machine manufacturing industry to which the main vendor (REIS) in the consortium belongs to. On top of that the INTELL-DIAG Products will be marketed to other sectors such as: shipbuilding, aerospace industry, etc. Here, one can distinguish as well large companies as SMEs. Market analysis: Based on the estimates of the potential exploitation of the large end-user in the consortium, an estimate of the potential market in the automotive sector (final car producers), which will be met, is about 100 products. The next potential market segment are suppliers of the automotive industry. An assessment of larger suppliers indicates the market volume to be met is about 40 products. On top of that the INTELL-DIAG Products will be marketed to other sectors such as: shipbuilding, aerospace industry, etc. A rough assessment of these market segments leads to an estimation of a potential market volume of a minimum of 150 products.
Extending INTELL-DIAG Diagnosis the INTELL-DIAG Maintenance is a tool for a set-up and repair support. It provides modules for the functionality below: - Set-up support, - Repair support, - On-line technical information support, - Failure prevention by maintenance scheduling based on expert knowledge and historical data, - Remote maintenance. The maintenance advisor is a remotely configurable software tool, which is based on the monitoring of machine performance and process parameters (part of the INTELL-DIAG Diagnosis Tool) to advise on required maintenance. It is developed following the extraction of diagnostic models and the building of the fault recognition and model-based diagnostic engines. The maintenance adviser will be integrated into remote user interfaces, the use of which requires security and authentication software or a private and secure Intranet. The application will provide a data history of the system in the case of failure to locate possible error sources by data analysis. The automatic data observation will allow alarm triggering at both end users sites and the robot manufacturer’s site. It is intended that monitoring of robot performance, process parameters and the reconfiguration of the automatic observation functions will be possible without involving user company personnel. It will be possible to retroactively correlate a product’s quality parameters and logged robot and process data, in order to ensure the stability of the process. The preventive maintenance process can be made significantly more reliable and efficient by remote monitoring of relevant system parameters and indicators and an enhanced knowledge base. The information and data gathered in the INTELL-DIAG Knowledge Base will provide the user with the required input information, which is often difficult to get, so enabling the user to use existing methods and tools on the market for planning preventive maintenance. The intelligent remote maintenance concept in INTELL-DIAG will improve the existing approaches and concepts applied by the users by a more sophisticated and extended knowledge base and experience of the system vendors. This will help to minimise the risk of unexpected system breakdowns in situations where the monitored signals and information do not provide signs of potential malfunctions, which are recognisable, based on state-of-the-art prediction methods. Potential applications: The main application domain is maintenance advisor in complex highly automated manufacturing systems, such as automotive industry. The main applications are: support in the set-up or repair of a machine/robot: set-up of a new machine/robot – relation to set-up process flow, repair of a machine/robot; remote maintenance: remote support in diagnostics after machine/robot messages, remote maintenance advises. End-users: The INTELL-DIAG Products will be first offered to the automotive sector since the large end-user in the consortium (DaimlerChrysler) comes from this sector and tools will be first applied at their plants. The next potential market segment are suppliers of the automotive industry. The second end-user in the consortium (ALUTECH) is representative of this segment. A distinguish must be made between large suppliers and SMEs in this sector. The third potential segment for the INTELL-DIAG Tools will be machine manufacturing industry to which the main vendor (REIS) in the consortium belongs to. On top of that the INTELL-DIAG Products will be marketed to other sectors such as: shipbuilding, aerospace industry, etc. Here, one can distinguish as well large companies and SMEs. Market analysis: Based on the estimates of the potential exploitation of the large end-user in the consortium, an estimate of the potential market in the automotive sector (final car producers) which will be met is about 50 products. The next potential market segment are suppliers of the automotive industry. Above assessment of larger suppliers indicates the market volume to be met is about 20 products. Potentials for selling the INTELL-DIAG Tool to the SMEs suppliers are very high: more than 80 products (but this will require scaling/adapting the system to their specific needs, which will require additional investment in the commercialisation phase, or may need an additional RTD project). On top of that the INTELL-DIAG Products will be marketed to other sectors such as: shipbuilding, aerospace industry, etc. A rough assessment of these market segments leads to an estimation of a potential market volume of a minimum of 100 products. However, the assessment of this market segment is less accurate than the other three segments, and INTELL-DIAG will primarily focus upon the first three segments.
The INTELL-DIAG Diagnosis includes modules for machine interfaces, malfunction detection module, set-up tool for knowledge repositories, user interface for error registration and error processing. They enable the execution of - Capturing of deterministic diagnosis models, - Remote machine monitoring, - Automatic malfunction detection, - Semi-automatic error registration and error details refinement, - Support in identification of the reasons of quality problems, - Local and remote automatic and manual malfunction diagnosis. By generic, standardised machine interfaces the information on products, on processes and A&R-facilities is measured and processed either at the plant or by remote monitoring tools. The automatic malfunction detection will notice the occurrence of specific malfunctions. Once the error is reported the error will be augmented with additional information automatically and by the user and stored into database where it will be picked up by the diagnosis tools. The errors can be quality and process problems detected by process facilities, PLC, malfunction detection logic and machine operators. The suspected cause will be reported and in INTELL-DIAG Maintenance the appropriate actions will be proposed. Taking into account different plants with varying machines and facilities and diverse computer networks the INTELL-DIAG Tools can be adapted to the environment due to flexible machine interfaces and flexible networking. The user interface for error registration is designed for a comfortable and encouraging usage by the machine operator. The knowledge repositories built up by automatic model extraction tools and based on distributed data bases contain the complex and scalable knowledge model about process, products and machines so that the diagnosis process is improved by refined models, which support the reasoning process immensely. Potential applications: The main application domain is diagnostics in complex highly automated manufacturing systems, such as automotive industry. The main applications are: Monitoring / optimisation of machines / processes, including identification of the problems and searching for the reasons of problems: ‘On-line’ reported problems: 1. Machine/robot diagnostic (fault) messages, 2. Automatic monitoring of the machine parameters, 3. Problem identified and reported by foremen or maintenance co-workers. ‘Off-line’: Problems identified based on the analysis of the process (e.g. statistical analysis). End-users: The INTELL-DIAG Products will be first offered to the automotive sector since the large end-user in the consortium (DaimlerChrysler) comes from this sector and tools will be first applied at their plants. The next potential market segment are suppliers of the automotive industry. The second end-user in the consortium (ALUTECH) is representative of this segment. A distinction must be made between large supplier and SMEs in this sector. The third potential segment for the INTELL-DIAG Tools will be machine manufacturing industry to which the main vendor (REIS) in the consortium belongs to. On top of that the INTELL-DIAG Products will be marketed to other sectors such as: shipbuilding, aerospace industry, etc. Here, one can distinguish as well large companies as SMEs. Market analysis: Based on the estimates of the potential exploitation of the large end-user in the consortium, an estimate of the potential market in the automotive sector (final car producers), which will be met, is about 100 products. The next potential market segment are suppliers of the automotive industry. Above assessment of larger suppliers indicates the market volume to be met is about 40 products. Potentials for selling the INTELL-DIAG Tool to the SMEs suppliers are very high: more than 120 products (but this will require scaling/adapting the system to their specific needs, which will require additional investment in the commercialisation phase, or may need an additional RTD project). INTELL-DIAG solutions integrated in the products of machine and robot vendors are likely to reach about 1000 within the first three years after they are put at the market. Also other market sectors are indicated as targets: shipbuilding, aerospace industry, etc. A rough assessment of these market segments leads to an estimation of a potential market volume of a minimum of 150 products. However, the assessment of this market segment is less accurate than the other three segments, and INTELL-DIAG will primarily focus upon the first three segments.