RESEARCH NEWS
New momentum for Linked Factory
EmulDan stands for ‘ Energy Efficiency in Production through Multivalent Data Usage .’ In this joint project , the Fraunhofer IWU and its industry partners demonstrated that significantly lower consumption process routes are achievable while maintaining component quality , even leading to shorter processing times in some cases .
“ When process design is consistently energy-efficient , maintenance efforts for production equipment also decrease . EmulDan focuses on how to collect data , providing valuable insights for both AIbased models and improved manual control options ,” said Fraunhofer IWU .
The ‘ Linked Factory ’
The ‘ Linked Factory ’ data architecture is a vision developed by Fraunhofer IWU for a comprehensive digital representation of all products , processes and machines within companies . This framework enables the integration of individual machines , logistics processes and building management systems . As a central element , a knowledge graph enables the connection of different data to generate real-time information .
“ Extracting information from large volumes of data properly means that individual data packets should support employees in their tasks , rather than add to their burdens . ‘ Contextual delivery ’ is the key phrase here , as the information needs of production managers differ from those of machine operators or maintenance technicians working on repairs . Therefore , each employee gets information tailored to their specific responsibilities . Central challenges in achieving a perfectly connected factory include intelligently linked controls and suitable interfaces to ensure all relevant data is extracted and fed back accurately ,” explained the research institute .
EmulDan focus
Alongside data architecture , the AI models developed in EmulDan represent a significant step towards comprehensive digital twins . In manufacturing areas with low automation levels , these machine-learning applications can support planners , decision-makers and production staff in their decision-making processes by highlighting trends . For example , ‘ drifts ,’ where the manufacturing of a component approaches tolerance limits , can be detected earlier .
In EmulDan , project partners focused on
Press hardening : heated sheet metal ( plate ) just before forming in the press . In the EmulDan project , energy-saving potentials are identified through targeted temperature adjustments within ranges of tolerance .
The energy-saving potential through digitalisation is particularly high in round bar knurling , reaching up to 70 per cent .
Image : © Fraunhofer IWU .
energy efficiency , ensuring that traditional metrics such as manufacturing time , cost and product quality did not deteriorate . Results achieved are now visible in demonstrators that highlight significant energy-saving potentials in manufacturing processes for hot forming , cold forming and machining .
Press hardening and hot forming
Press hardening combines the advantages of forming and heat treatment in a single step . It enables the production of high-strength , lightweight body parts ( such as B-pillars in cars ). In the project , a boron-manganese sheet was heated to over 900 ° C and then formed and cooled in a die . The rapid cooling during and after forming transforms the material structure into a martensitic form , resulting in high hardness and strength .
“ This manufacturing process consumes a lot of energy , so exploring the saving of opportunities is logical . For data-driven process control , project partners collected all relevant manufacturing data from individual processes and process chains and created process models to predict energy needs and component quality across various optimisation scenarios . Hybrid process models based on digital twins proved particularly beneficial , resulting in potential energy savings of up to 20 percent by combining several adjusted process parameters ,” outlined Fraunhofer IWU .
Other processes
Image : © Fraunhofer IWU .
Round knurling is suitable for producing various lightweight shapes . Typical applications in the automotive sector include steering spindles , drive shafts and airbag cylinders .
EmulDan also demonstrated significant energy-saving potential for this forming process . The partners focused on supplementing the previously unregulated , primarily quality-focused , experience-based process parameters with energy-relevant aspects .
“ This approach helped design a software tool for data processing that enables self-learning process correction and creates suitable models for forecasting . It identifies relationships between machine parameters , component quality and energyrelated process metrics , translating them into process models that aim for overall optimisation . In practice , this means better process understanding and the potential for energy consumption reductions of up to 70 per cent ,” added Fraunhofer IWU .
In processes such as turning and smoothing , high safety factors often guarantee that components comply with specifications and can be produced even under unfavourable conditions . In EmulDan , sensors integrated into tool holders provided data for assessing tool conditions and processes , forming the basis for significantly reducing many safety factors . The project partners demonstrated that a main times reduction of 50 per cent is feasible . As a positive side effect , much testing becomes obsolete and process reliability increases . n
18 | ismr . net | ISMR November 2024