A review of IOT and Industry 4.0 in Japanese vibration application

Transcription

1 1 A review of IOT and Industry 4.0 in Japanese vibration application APMP TCAUV Workshop 2017 Applying Acoustics, Ultrasonic and Vibration Metrology to Intelligent Machine for Industry 4.0 Hideaki NOZATO, Ph.D. National Metrology Institute of Japan (NMIJ) Vibration and Hardness Standards Group

2 2 Conceptual structure of Industry 4.0 CPS (Cyber physical system) Cloud Management ERP MES Manufacturing sector SCADA Fog PLC Edge CNC machine Machine tool I/O FA machines, sensors.. Cover-all optimized control of product development Monitor and Control of manufacturing process Control of machine and sensors

3 3 Action and name of each country in manufacturing field Name Industry 4.0 AMP, IIC 製造大国 2025 Society 5.0 Country Germany United States China Japan Core systems of 11 ones in Society Advanced road communication system 2. Energy value chain 3. Manufacturing system AI, IoT and Big data support the core systems. That is a main topic of this workshop.

4 Issues of manufacturing machine in Industry 4.0 The purpose of industry 4.0 is to assemble various information and to implement the optimization in total. But, the most difficult issue is to expect operational conditions of the manufacturing machines and to certify the manufacturing performance. Learning and tuning of manufacturing machine Geometrical error 30 m 3 m 4

5 5 Importance of compliance of mechanical system Excitation and measurement system Compliance is a kind of transfer function with the unit of m/n. Compliance means the stiffness of the main rotational axis. F is given by the piezo element, and acceleration is measured by accelerometer. F k D compliance 1 k D F Small compliance ~ soft Large compliance ~ hard Hard is important for machine tools, because the stiffness is high.

6 6 Evaluation of compliance of mechanical system Excitation and measurement system It is important to investigate the compliance of the mechanical system including the force sensor. By using accelerometer or impulse hammer, the dynamic stiffness of the mechanical system is evaluated to estimate chatter vibration.

7 Confidential Problem of chatter vibration in machine tool Chatter vibration: The vibration by cutting force couples with the inherent vibration that the machine tool has. With chatter vibration Without chatter vibration Rotational speed Cutting force Reasons of chatter vibration What material to be cut Machine tool to cut Main rotational speed of machine tool Cutting speed, etc Until now, engineers cut material using machine tools on the basis of their know-how and experiences. Machine Learning 7

8 Major industries expected to contribute to machine tools Response to Society Realization of sustainable society Transportation system Expected Industry Automobile Train Airplane Shipbuilding Construction Civil engineering Handling machine Others Hybrid, Fuel Cell, Electricity Express train and its infrastructure Regional Jet, Fuel Efficiency Fuel Efficiency, Speeding Up Use of GPS Fork Lift, Crane Energy system Population explosion and aging population with fewer children Energy Industry Atomic Power Wind Power, Solar Light, Fuel Cell, Biomass Radioactive Waste, Safety Globalization Information Technology ICT, IOT Medical Related Agriculture, Food Nursing care welfare Medical Equipment, Implant Parts Businessization of Agriculture High Automation of Food Machinery Use of robots 8

9 9 Introduction of today s topics Core systems of Society Advanced road communication system Judgement of train operation control in earthquake Already presented in APMP DEC workshop 2014 Wheel flat detection device 2. Energy value chain 3. Manufacturing system Learning robot Collaborative robot with human Intelligent machine tool

10 Emission of carbonic dioxide (kg/person) Carbon dioxide emissions to carry one kilometer per person Train is the most energy-saving way in traffic infrastructure Automobile Airplane Bus Train [Ref.] 10

11 Wheel flat detection device Wheel flat gives undesired noise or bad ride comfortability, damage of carriage. Because the wheel is out of round. Big Noise Wheel flat (image) 2 Expanded wheel flat Flat part 1 と 2( 著作権フリー ) はインターネットから流用 3 は弊社独自写真 11

12 How to detect wheel flat 1. Attach accelerometer to sleeper 2. Measure generated vibration and shock when a train passes on the sleeper 3. Detect a wheel flat accelerometer 4 sleeper 4 の写真は弊社独自写真 12

13 After-treatment of wheel flat detection 1. Analyze the existence of wheel flat after the measurement data are transferred to analysis device. 2. If wheel flats are found, the analysis device shows which number of wheels there is a flat. 3. Railway companies implement to rotate the wheel flat. That contributes to reduce undesired noise, to enhance ride comfortability on the train and to avoid damage of other wheels. Attention Wheel flat On-site measurement Network server According to the analysis result, I repair the wheel flat. 13

14 14 Introduction of today s topics Core systems of Society Advanced road communication system Judgement of train operation control in earthquake Already presented in APMP DEC workshop 2014 Wheel flat detection device 2. Energy value chain 3. Manufacturing system Learning robot Collaborative robot with human Intelligent machine tool

15 Market volume (million USD) Robotics market volume The market volume is expected to be 100 billion USD in Manufacturing Robotic technology Agriculture, Forestry and Fisheries Service

16 16 ISO documentation for collaborative robot with human Conventional regulation In case of operating power of the robot with more than 80 W (150 N), the use of safety net is required to protect human. ISO : 2011 (JIS B8433-2: 2015) Robots and humans can work together without safety net in case of the robot with any one of following conditions satisfied. 1. Safety-rated monitored stop ( ) 2. Hand guiding ( ) 3. Speed and separation monitoring ( ) 4. Power and force limiting by inherent design or control ( )

17 17 Confidential Image of collaborative robot with human Conventional robot Collaborative robot

18 18 Confidential Robotics by utilizing IoT and AI

19 19 Confidential Bulk robot, Force-controlled robot Bulk robot can take out bulk parts one by one from the basket. 6-axial force-controlled robot can contribute following situations. バリをグラインダーで削り取る作業 部品表面を研磨する作業 シャフトを穴へ精密にはめ込む作業 歯車同士を組み付ける作業 etc...

20 20 Confidential Learning robot According to below figure, learning robot can weld the spot by suppressing vibration displacement around 10 mm with accelerometers. Before learning After learning

21 Cutting force 21 Frequency region of chatter vibration Chatter region Non-chatter region Rotation speed Cutting force The tool strains by cutting force or rotational speed. Rotational speed Main axis of tool As an evaluation way to calculate the cutting force, Conventional : rigid body model New approach : tool dynamic deflection model

22 22 Confidential Relation between cutting error and surface roughness Information of compliance is required for the tool dynamic deflection model. Each maximum compliance Holder A : 26.6 m/n (2072 Hz) Holder B : 11.9 m/n (1950 Hz) There is a correlation between cutting error and surface roughness. Machining error depends on the maximum compliance.

23 Confidential Effect of with model (tool dynamic deflection model) With model get better cutting error from several tens of m to several m. 23

24 24 Confidential Estimation concept of sensor-less cutting force Loading force (cutting force, friction) Motor electric current (input) Servo motor Motion control Disturbance observer Position / Angle (output) Estimated disturbance *The disturbance is estimated from input and output signals.

25 25 Confidential Estimation result of sensor-less cutting force Force resolution: several N Frequency resolution: 2 khz

26 26 Summaries and prospects Society 5.0 makes an importance on advanced manufacturing technology with IoT optimized. The most difficult issue is to certify the manufacturing performance by learning various information with IoT. By using tablet, accelerometer and force sensor, the optimization and visualization are carried out in a factory.