Industry 4.0 Facing the challenge in CONACYT Public Research Centers

Transcription

1 International Nanoforum Industry 4.0 Facing the challenge in CONACYT Public Research Centers Vicente Bringas Rico

2 Strategic Plan of CONACYT for Public Research Centers

3 Thematic Alignment Advanced Manufacturing and Industrial Processes Coordination DACI Dirección Adjunta de Centros de Investigación Environment, Food Production and Biotechnology Coordination Economy, Public Politics and Regional Development Coordination History and Social Anthropology Coordination Physics, Applied Mathematics and Information Technology Coordination

4 Thematic Alignment (DACI CONACYT) CONACYT Centers System Re-engineering Scientific Plan Be a tool of the Mexican state to solve national problems on knowledge Basis Programas de Investigación de Largo Aliento (PILA) Technological Plan To be an engine of the country development through the technological attention to key sectors of the economy Estrategia de Centros para la Atención Tecnológica a la Industria (ECATI) became on Consortium basis

5 Joining strengths to serve the market Manufactura Avanzada Cambio Climático y Sustentabilidad PILA Long Term Research Programs Cd. del Carmen Hydrocarbons Campeche * * CENTROMET Metropolitan Studies Querétaro Consortium MHT SLP Nature of the Universe Society and Development CENTA Aeronautics Querétaro Renewable Energy Durango CITTAA Automotive Aguascalientes * Leader CIDESI

6 World initiatives analysis on Advanced Manufacturing and I4.0

7 1 st 2 th 3 th Industrial Revolution and Society Evolution First mechanical loom, steam power First mass production assembly line, electricity First Programmable logic controller (PLC) Factory connected, Hannover 2011 INDUSTRY Industry Beginning of humanity 13,000 A.C End of 18 th Century End of 20 th Century SOCIETY From 21 th Century Society Hunting Society Agrarian Society Industrial Society Information Society Super Smart Society

8 Knowledge Areas Cloud Simulation and modeling Cybersecurity Augment reality INDUSTRY Cyber physical systems and spaces Integration Systems Internet of things (IoT) Additive Manufacturing Autonomous Robots and Artificial Intelligence Smart Materials

9 Keidanren (Japan Business Federation): Toward realization of the new economy and society Falling population Decline of industrial competitiveness Smart Society SOCIETY Super aging society Lack of women s active participation Society in which every individual including elderly people and women can actively participate Disasters Terrorism Decrepit infrastructure Safe and secured society in both cyber and physical spaces Environmental problems Lack of resources and water Society that contributes to the solution of global environmental issues

10 EUROPEAN FACTORIES OF THE FUTURE RESEARCH ASSOCIATION A Manufacture initiative Sub-domain 1.1 Processing novel materials and structures (into products) Sub-domain 1.3 Business models and strategies for disruptive manufacturing process Manufacturing for custom made parts Advanced joining technologies Photonic process chains New models for introducing disruptive processes Automated production Surface manufacturing processes Materials-efficient manufacturing processes Sub-domain 1.2 Complex structures, geometries and scale Robust micro and Nano enabled production Novel supply chain approveches for innovative products Product life cycle management for advance materials High Volume Manufacturing at the micro- and nano-scale

11 H2020 Technology Enablers Challenges and Opportunities Research and Innovation Priorities Advanced Manufacturing Processes Mechatronics for Advanced Manufacturing Processes Information Technology and Communications Manufacturing Strategies Modeling, Simulation and Prediction Tools and Methods Knowledge Workers

12 Market opportunities, Long Term Research Programs and Consortiums

13 The double implication American theoretical physicist John Archibald Wheller says: Spacetime tells matter how to move; matter tells spacetime how to curve. In the same way: Technology tells market how to move; market tells technology how to response. V. Bringas

14 O p p o r t u n i t y A r e a s INDUSTRY Augmented Reality Simulation and Modeling Product Process Industrial monitoring and maintenance Training and qualification Costumer interaction and design Internet of Things (IoT) Smart Materials Self-healing materials Reconfigurable materials Domotics Transport applications Monitoring applications Tracing people and objects Security applications Integration Systems Manufacturing applications Health applications Customer products application Ciberphysical Systems and Spaces Product Process Additive Manufacturing Cybersecurity Laser cladding Hybrid manufacturing Powder development Development of models, software and protocols Robots Inspection and monitoring robots Industrial robotics, high risk environments Agro-robots Artificial Intelligence algorithms Big Data Data analytics Data mining

15 National Development Plan PECiTI Financing PILA I Big National Problems Advanced Manufacturing TRL 1 y 2 Basic Research (Ciencia Básica y Fronteras de la Ciencia) TRL 3 y 4 Applied Research (Problemas Nacionales) + D+i ECATI Thematic Consortiums Hydrocarbons Aeronautics Molds, Stamping and Tooling TRL 5 al 7 Technological Development (PEI, FORDECyT, FOMIX) TRL 8 y 9 Integration Engineering and Technological Services (Direct Contracts)

16 Advanced Manufacturing PILA (research lines) I.- Advanced Manufacturing Technologies - Additive manufacturing and 3D printing - Advanced forming and joining technologies - Micro and nano manufacturing - Advanced thermal treatments - Advanced materials and coatings - Virtual manufacturing - Conventional and next generation manufacturing methods II.- Intelligent Manufacturing - Sensing, actuation, monitoring, measurement inspection and automation - HMI, M2M Interfaces, collaborative, adaptive and cognitive robotics - Embedded systems, adaptable, intelligent and cognitive control - Mobile applications and Internet of Things - TIC s, software, SCADA and Big Data

17 Advanced Manufacturing PILA (research lines) III.- Intelligent Maintenance and Management - Remote monitoring - Self- diagnosis, Self-adjustment and self-repair - TIC s, Software, SCADA and Big Data IV.- Sustainable Manufacturing - Renewable and Conventional Energies - New Materials - Intelligent and Self-Healing Materials V.- Cyber Security on Industry Regulatory standards and framework operations for Industry Cyber Physical systems security - Vulnerability Management - Security and reliability on telecommunications

18 Contribution capabilities Market Needs Advanced Manufacturing PILA Theme 1: Advanced Manufacturing Techniques 1 Research Line: Additive Manufacturing 1. Molds repair 2. Complex geometry molds manufacturing 3. Alloys development for high performance coatings 4. Thermal treatment for active materials deposited by additive techniques 2 Research Centers with experience on the research line joint venture PILA and Consortium relationship 5 Ad hoc solutions for the market PILA s research lines aligned to Consortium 1. Alloys and powder development 2. New deposit methods development 3. Alloys and final components characterization 4. Modelling and simulation of manufactured components 5. Thermal treatment 6. Monitoring and inspection 4 Research Proposals Molds, Stamping and Die tools Consortium - Laser Cladding manufacturing and repair - CMT mold repair San Luis Potosí 3

19 CIDESI Alignment plan to attend the market

20 Technological Themes CIDESI Additive manufacturing and 3D printing Advanced technologies for molding and union MEMS Advanced thermal treatments Surfaces engineering Virtual Design and Manufacturing Assembly, manufacturing and test equipment development Advanced and conventional materials development and characterization Last generation and conventional manufacturing processes Thermodynamics and energy Manufacturing 4.0 Advanced Manufacturing Techniques Real Time Information TIC s, software, SCADA, Big data Mobile applications Internet of Things Robotics, Automation and Intelligence Monitoring, measurement and vision HMI and M2M interfaces Conventional, adaptive, cognitive, collaborative and inspection robotics Embedded systems and sensors Cognitive, adaptable and intelligent control Production management, logistics and supply chains Auto-diagnosis, auto-adjustment, auto-repair Advanced instrumentation

21 Thermal Treatment Surfaces treatment Correlation Diagram for Surfaces Engineering Direction Additive Manufacturing Advanced Manufacturing Techniques Modelación y Simulación Monitoring and measurement HMI Robotizing Robotics, Automation and Intelligence CAD, CAM, CAE Materials Characterization Additive manufacturing (Cladding, EBM, DMLS, etc.) Advanced thermal treatments Surfaces treatment Materials Modelling and simulation Characterization Real Time Information HMI Robotizing CAD CAM CAE Monitoring and Measurement

22 Project analysis example: Robotized assembly line (part 1) Environmental, social and economic impacts Sales increment $ Earnings $ New jobs with higher added value generated Low power consumption and low environmental impact Research Center ideal model Advanced Manufacturing PILA I. Advanced manufacturing Techniques - New production methods II. Intelligent Manufacturing - Collaborative robotics - M2M interfaces - Automation Knowledge application Human resources training Industria 4.0 Knowledge generation Technological services Technological themes Intelligent Manufacturing Simulation and modeling Autonomous Robots and Artificial Intelligence Advanced Manufacturing Techniques Robotics, Automation and Intelligence Business Line Assembly, manufacturing and test equipment development Monitoring, Measurement and vision M2M and HMI interfaces Collaborative and Industrial robotics Automated Systems Direction Lean manufacturing lines for automobile industry

23 Project analysis example: Robotized assembly line (part 2) MEMS Surfaces Engineering Laboratory Infrastructure Present and required Augmented reality I4.0 Personnel training opportunities Specialist training opportunities Laser technologies Sensors Software Project specialists Cyber physical Spaces New Business Offer To offer tooling with high performance coatings To offer production management systems To offer smart line with mobile applications Tooling New Business opportunities Production Management Smart line Diseño Mecánico Personnel s experience Análisis estructurales Programadores Electricos Mecanizados Ensamble y pruebas Experto Medio En formación

24 How to define a I4.0 project for the industry

25 Industry 4.0 project definition topics Functional: Mission, performance, user needs Configuration: Parts, modules, accessibility, interchangeability Interfaces: Equipment, process, systems, users Physical: Weight, Size, material, CoG Environmental: Acceleration, temperature, humidity Quality: Reliability, maintainability, availability, usability Project I4.0 Product or Process Operation: HMI, M2M, manual, automatic, intelligent Support: Maintenance, training, logistic, post-selling Verification: Test, inspection, monitoring Energetic: Type, energy saving, energy harvesting Sustainability: Impact, health, environment, lifecycle Connectivity: In cloud, Wi-Fi, satellite, Bluetooth

26 Example for I 4.0 project definition: Engine entrance air manifold Problem: Manifold re-engineering project: Material change to increase thermal resistance to C, flow sensor integration during the injection process located inside a new flow improved chamber. Requirement Description Solution available Development need I4.0 Project Impacts Functional Improve internal chamber air flow, for fuel saving Yes Injection mold with the capability to integrate flow sensor during the injection process Fuel consumption saving with the final customer. Additional 100,000 parts per year sales increment Physical characteristics Design changes on internal flow chamber increases complexity an costs during traditional machining of production mold Yes: To use additive manufacturing for injection mold fabrication New process development including tooling (injection molds) Injection mold manufacturing by additive technique Cost saving on mold manufacturing Environmental Temperature resistance increment from 80 to 150 Yes Polymer new formulation No Useful life increment on the final part with the subsequent customer satisfaction Verification Embedded sensor on internal flow chamber No Flow sensor development Injection process design Mold design and manufacturing New injection process and tooling development Sensor development Fuel saving due to direct measurement on flow chamber. Customer satisfaction Sustainability Design with low energy recycling material for final disposal Yes Polymer new formulation No Cost saving and environment impact

27 Conclusions

28 Customer expectations on Industry 4.0 The promise to customers is customized or personalized products delivered rapidly, with perfect quality at ever-decreasing prices. The promise to shareholders is the opportunity for greater revenues and higher margins. The promise to suppliers is for expanding volumes, with clear and immediate electronic information about orders, performance and upcoming design needs, and payments. The promise to employees is for more interesting and strategic work, and the assurance that the company is meeting customer demands so is likely to continue to employ them. Source: Industry Week, American Machinist, sponsored by EPICOR

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