industry 4.0 at smart machine and intelligent machine...

Wen-Yuh Jywe

Chair Professor / President

Smart Machine and Intelligent Machine Research Center

National Formosa University

Taiwan, ROC

Industry 4.0 at Smart Machine and Intelligent Machine Research

Center : Laser R-Test and Smart Machine Engine

1. Introduction: Smart Machine and Intelligent

Machine Research Center (SMIM) at National

Formosa University (NFU)

2. The Current Developments of SMIM Research

Center

3. Application of Laser R-test to the accuracy

measurements of five-axis machining centers

4. Functions of Smart Machine Engine Developed

for Intelligent Manufacture

5. Conclusions

CONTENTS

Introduction: Smart Machine and Intelligent Machine Research Center (SMIM) at National Formosa University (NFU)

National Formosa University (NFU)

sparc.nfu.edu.tw/~pmc/ 4

Established Year : A.D. 1980

President: Dr. Wen-Yu Jywe

Full-time Faculty Members: 325

Students: 10,189

Location: Huwei Township, Yunlin County, Taiwan

Web Site : www.nfu.edu.tw

Resume個人履歴


Experience

1. President, National Formosa University (NFU).

2. Distinguished Professor (Department of Automation Engineering, NFU).

3. MOE- Committee Member of : Accreditation of Technical Education and Technical Universities.

4. MOEA- Committee Member of :a. A+ Industrial Innovation R&D Program for Industry;b. Precision Machine Industry Development.

5. MOST- Committee Member of :a. Intelligent Machine and Aerospace Industry Upgrade Program;b. Innovation and Application of Nanoscience Thematic Program.

Education

Ph. D. Mechanical Engineering, University of Manchester Institute of Science and Technology, UK, 1992.

Expertise 1. Metrology2. Integration of Automation Equipment 3. Precision Measuring and Feedback Control


Location & Access

4 km

2 km

Main Campus

New Campus

THSR Taoyuan Station

Taoyuan Int’l Airport

THSR Taoyuan Station

THSR Yunlin Station

NFU

20 min (Train)

70 min (THSR)

12 min (Taxi)

Machine Tool Valley

Academic Programs 学術プログラム


4 Colleges

19 Departments

18 Master’s Programs

2 Ph.D. Programs

Mechanical and Computer-Aided Engineering Automation EngineeringPower Mechanical Engineering (Ph.D.) Vehicle EngineeringMaterials Science and Engineering Aeronautical EngineeringMechanical Design Engineering

Electro-Optics Engineering (Ph.D.)Electrical EngineeringComputer Science and Information EngineeringElectronic Engineering

BiotechnologyLeisure and RecreationMultimedia Design Applied Foreign Languages

Industrial ManagementInformation ManagementFinanceBusiness Administration

Engineering

Elec. & Comp. Engineering

Ma

na

gem

ent

Ap

plied

Arts &

S

ciences

NFU

Smart Machine and Intelligent Machine Research Center (SMIM)


Five-years industrial-academic collaboration

23 cases of Technology transfer (total USD 1.33 million) ;

49 cases of Industry-requested plans (total USD 4.73 billion;

127 patents obtained (US:11; EU:3; JP:2, CN:2; KR:1);

8 commercial products has developed, such as Laser R-Testand Smart Machine Engine.

SMIM Research Center at NFU was created in 2003.

Laser R-Test Smart Machine Engine



Current Projects MOEA - Industry-Academia Flag-Ship Team Project: Industry-

academia cooperative research Project for intelligent manufacturing of machine tool based on value creating and application implementation (USD 7.79 million; 5 Universities, 11 Companies, and 2 Research Institutes)

MOST – Global Liaison Project: The alliance of advanced manufacturing for the aerospace processing supply chain (USD 1.94million; 19 Companies)

MOE - International Academy of Technological Talent Cultivation Project (USD 6.47 million; 1 Foreign university)

MOE - Higher Education Enhancement Project - Characteristic Center Project (USD 6.47 million; 1 Foreign university)

ISO 17025 Accredited Laboratory Second machine tool laboratory accredited by

Taiwan Accreditation Foundation (TAF).


Research Staff (~2018.10)

Director: Wen-Yuh Jywe

Professors: Ying-Chien Tsai, Ruei-Chang Lin, Bean-Yin Lee, Jing-Chung Shen,Bor-Jeng Lin, Sheng-Yung Lin, Young-Huh Sheu, Jeng-Nan Lee,Yung-Cheng Wang, Wen-Chi Lu, Jeng-Dao Lee, Chen-Hua She,Ming-Tzong Lin, Ji-Han Jiang, Meng-Tse Lee, Chun-Jen Chen.

Postdoctoral Fellows: Tung-Hsien Hsieh, Hsueh-Liang Huang, Chir-Jang Tsai.

Research Engineers: Bing-Chi Jan, Tsu-Te Hong, Chia-Ming Hsu, Tung-Hsing Hsieh, Jia-Hong Chen, Yen-Chieh Wang, Yu-Wei Chang, Ching-Ying Chiu, Sen-Yi Huang, Yung-Chuan Huang, Chao-Yuan Lin, Yung-Yi Huang,Ming-Sung Hsieh, Cheng-Chung Tseng, Wen-Qian Lin, Kuan-Liang Kuo, Chin-Tsung Chen, Shih-Hsiang Lin, Tzu-Hung Chen, Kai-Wei Chang, Ling-Yu Tsai, Keng-Chiang Liao, Yuan-Han Chang, Hsin-Hung Hou, Shang-Kai Liao, Chien-Wei Chen, Chia-Yun Chuang, Po-Chieh Hong, Yung-Li Chen, Po-Yu Chen, Kao-Chuang Chen.

(Total 16 Profs.6 Depts.)

(Total 3 Postdocs)

(Total 32 Engineers)


Awards in the Recent 10 years• Outstanding Research Award, Ministry of Science and Technology,

2017.• Research award from Machine Tool Engineering Foundation,

Japan, 2016.• The Academia-industry contribution Award for machinery industry

from Taiwan Association of Machinery Industry, 2016.• Distinguished Academia-industry Collaboration Award from

Ministry of Science and Technology, 2014.• National Invention Gold Award from Ministry of Economic Affairs,

2012.• The prize of technology transfer Award from Ministry of Science

and Technology, 2012.• 2nd National Industrial Innovation Award from Ministry of

Economic Affairs, 2012.• The Academia prize of best researcher Award from Ministry of

Science and Technology, since 2010.• The Academia contribution Award for industry economy from

Ministry of Economic Affairs, 2009.


Industry Collaboration


The Current Developments of SMIM

Research Center

Smart Manufacture Development at SMIMIndustry 4.0 Flagship Project (USD 7.79 million)


Partners Relationship

Machine Tool Industry Productivity 4.0

DOIT, MOEA

System Companies Key Component Companies

End Users

Cooperation

Industry Alliance

Business AssociationAcademia Society

UniversitiesResearch Institutes

SMIM Development Items Development of an Smart Machine Tool


Robot

e.g. Management of Tool and Fixture

e.g. Identificationof Personnel

e.g. Inspection,load & unload

e.g. Rotary Axis Accuracy, Geometric Accuracy

e.g. Servo parameters, Power loading

Sensor

e.g. Vibration, Temperature

e.g. Manufacture Traceability Manufacture Scheduling

e.g. Machining Time,Availability

e.g. Tool selection, Machining Path

Auto-Machining

User Interface

Machine Status

Compensation

QR Code

RFID

Controller

Value-added Software

Communication

Laser R-Test

Smart Machine Engine

Controller

Ethernet

Smart Machine EngineInternal Sensing: Controller Parameters

MT ConnectOPC UA

Laser R-TestWireless Sensor

External Sensing: Temp., Vibration, Sound

Machine Learning:1. Accuracy Model2. Automatic

Compensation3. Work Prediction4. Diagnosis

Artificial Intelligence

DBPrediction Mode

SMIM Development Items Development of an Smart Machine Tool


SMIM Development Items Functions of an IoT Environment Developed for Intelligent Manufacture


Laser R-Test

Smart Machine Engine

Wi-Fi/BLE

Laser R-Test + CNC + Robot + RFID Reader + QR Code Reader

OPC UA

Data Communication of the Inspection and Compensation for a Machine Tool

Communicating and monitoring of the intelligent manufacturing line

Intelligent ManufactureManagement

SchedulingOperation

Robot Tool LifeSmart Machine

Engine

• Site I. Aerospace Parts Manufacture Development

Industry 4.0 Demonstration SitesCurrently, 12 machine tool manufactures (including FFG) arecooperating with NFU for conducting the MOEA Industry-AcademiaFlag-Ship Team Project.

about 30 seconds

1. The M2M and M2R connectionare conducted by Smart MachineEngine Technology;

2. Laser R-Test is utilized for themeasurement and compensationof machine tools.

This site comprises 3 machine tools and 1 Robot. The controllers utilizedare FANUC, HEIDENHAIN, and SIEMENS. In this site:


• Site II. PC-based Controller (Taiwan) Development

Industry 4.0 Demonstration Sites

This site comprises 3 machine tools and 1 Robot for development of value-added software. The controllers utilized in this site are ITRI(工研院 ),SYNTEC(新代), and LNC(研華寶元).

• Site III. Tool Manufacture Development This site comprises 6machine tools and 1Robot for the researchof tool design, cuttingefficiency, tool-lifemanagement.


Industry 4.0 Demonstration Sites• Site IV. Intelligent Manufacture for Metal Machining

This site comprises 3 machine tools and 1 Robot to develop of the turnkeysolution of aerospace parts machining for Evergreen Aviation Precision (長榮航宇) and Magnate Tech (晟田科技).

1. The M2M and M2R connection are conducted by Smart Machine Engine Technology;

3. This site was built inthe factory of Taiwanmanufacturer.

2. Laser R-Test is utilized for the measurement and compensation of themachine tools;


Application of Laser R-test to the accuracy measurements of five-axis machining centers


Laser R-test (LRT) can quick calibrate three-axis and five-axissynchronous motion performance of a five-axis machine tool. Itcan be applied to various types of machine calibration needs.This system is equipped with user-friendly software that canperform wireless operation in a non-contact manner. In addition,no specialized knowledge is required for the measurement andcompensation of LRT, so everyone can operate LRT easily.

Resolution: 0.05 µm System Accuracy: 0.5 µm Measurement Range: ±100 µm Sampling Frequency: 1~40 kHz

Specification

Overview

Overview


The tolerance displacement between thereference glass sphere and sensor moduleof Laser R-Test is reaching up to ± 20mm which is 100 times than that of IBSR-test system with an expensive referencemetal sphere. Therefore, the danger ofaccidentally colliding with the sensormodule is quite low. Furthermore, theaccidentally damaged reference glasssphere could be easily replaced with thenew one by the user, the system halteddue to accidental collision can be quicklyrestored.

Functions Comparison


Functions ISO LRT IBS LION XR-20W AxiSet

Static Eccentricity Calibration 10791-6 ✔ ✔ ✔

Dynamic Contouring Calibration 10791-6 ✔ ✔

Component Errors of Rotation

Axis for Work table10791-1 ✔ ✔

Backlash 230-2 ✔

Angular positioning 230-2 ✔ ✔

Thermal Drift and Spindle Runout 230-3 ✔ ✔

Off-line,Spindle Runout Measurement($NTD 2,000,000)

LION Spindle Error Analyzer

Off-line,Accuracy meas. for Rotation Indexing ($NTD 1,800,000)

RENISHAW XR20-W

Off-line,Eccentricity Meas. for Rotary axis($NTD 150,000)

RENISHAW AxiSet™ Check-Up

Off-line, 3DMulti-axis Static &Dynamic Meas. ($NTD 1,800,000)

IBS Rotary Inspector

LRT


2008 1st Generation: Originally named as “NON-BAR”.

2010 1. 2nd Generation: Module simplification.2. Patent pending started .

2009 Start machine tools compensation services in Taiwan.

2012 1. 3nd Generation: Sensor upgraded.2. Japan, EU, and China Patent obtained.3. Journal paper “Non-bar, an optical

calibration system for five-axis CNC machine tools ” has published.

2014 1. 4th Generation: L-type glass ball-bar.2. Taiwan and USA Patent obtained.

Overview


2015 1. Angular Positioning compensation and automatic compensation were developed.

2. Automatic compensation: SIEMENS, FANUC, and HEIDENHAIN controllers.

262016 1. Automatic compensation:

MITSUBISHI and ITRI.2. 5th Generation: Wireless version.3. Renamed as “Laser R-Test (LRT)” by

TUAT Prof. TSUTSUMI.

2017 1. New module developing: Spindle rotation –Axial thermal drift and wobble inspection

2. New User Interface developed.

Overview

2018 1. On-line measurement of BK1 and BK2 path.2. BK1 + BK2 path measurement.


Application Performance of Laser R-TestA

ver

age

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r o

f fi

ve-

axis

sim

ulta

neo

us

mo

tio

n (

K4

pat

h)

afte

r co

mpe

nsa

tio

n (μ

m)

Cum

ulative am

ount o

f measu

remen

t data

(set)

B-type A、B、C type New Sensor L-type Stem WirelessCharacteristicsNew Interface andMeasurement Path

Overview

Application Fields


Five-axis Machine Tool Measurement and CompensationRobot Measurement and CompensationSpindle Runout and Dynamic Accuracy

SpindleRobotFive-axis Machine Tool

Applicable Machine Type


Annex A: Universal spindle head

Annex B: Tilting rotary table

Annex C: Mixed

LRT can be applied to turning-milling complex machine tools and 5-axis machine tools specified in the annex A, B, and C of ISO 10791-6.

Applicable Machine Type


LRT can be applied to turning-milling complex machine tools and 5-axis machine tools specified in the annex A, B, and C of ISO 10791-6.


Laser R-Test has applied to machinetools inspection for over 15000 timesto all the machine tool builders andusers in Taiwan (such as FFG, Litz,Quasar), Japan machine tool builders(such as MAZAK, OKUMA, DMGMORI, and MAKINO), FraunhoferIPT, and RENISHAW.

Service Situation

LITZVICTOR TAICHUNGYIDA RENISHAWFraunhofer IPT

MAZAK OKUMA

Functions of Smart Machine Engine Developed for Intelligent Manufacture

Overview


The traditional factory requires a large manpower to monitor the machineall the time, which is hard to control the utilization rate and productionschedule, etc. It causes waste of manpower and utilization of machines.Thus, with installing this system, labor costs can be greatly reduced andproduction quality can be improved.

Overview


Smart Machine Engine (SME) is mainly focusing on integrating existed industry-related technologies, sensors and smart compensation to build smart factories withrapid integration, high intelligence and human resource efficiency. Its technicalfoundation is the integration of the Internet of Things (IoT) and mobile devices, andthe use of the German industrial communication protocol OPC UA to connect themajor controller brands in series (including Robot, CNC and PLC).

Overview


System StructureSME can be divided into three categories: Smart Machine Server (SMS),Smart Machine Client (SMC), and Smart machine Box (SMB). It is benefit forestablishing application services of management and control, and improvingthe efficiency and yield rate of production line.


1. Sensing Devices: Sensing Signals can be conducted by machine external.2. International Standard: Supporting

OPC UA protocol and multiple third-party software.

3. Single machine application: Remote I/O control, machining program transmission, compensation feedback, MARCO reading and writing, and expandability of measuring instrument.

4. Utilization Rate Calculation: Machines’ status parameter and utilization rate of single machine.

5. Advanced Planning and Scheduling (APS)： Supporting to schedule work orders by using genetic algorithm according to three.

Instantly Status

Querying

Dispatching orders

dynamically

Features

Overview

Introduction of SMS


Smart Machine Server is mainly connecting controllers of CNC, Robot, or PLC,and other related sensors through OPC UA specification of internationalcommunication format to convert into a secure communication mechanism,which providing people to be online at the same time and can be networked onmultiple platforms. Through this mechanism, all the equipment in the factory canbe connected rapidly and can develop more related application services.

Note: The provided functions will be varied depending on the different machine tools and lathes.

Introduction of SMS




Introduction of SMC


Main Functions

Introduction of SMC


Available Items of Monitoring

Introduction of SMC


Factory Field Distribution Factory Monitoring

Machine Tool Controlling Robot Monitoring

Introduction of SMC


Robot I/O Control PLC Monitoring

RS232 Monitoring Utilization Monitoring

Introduction of SMC


ProductionScheduling

ToolManagement

Conclusions

The geometric error of five-axis machine tool canbe auto-compensated using the Laser R-Test.Because the distance between the referencesphere and sensor of LRT is reaching up to ±20mm, so the reference sphere collision problemcould be effectively prevented. Users can easilyand quickly replace the accidentally scratchedreference sphere with the new one; therefore, themeasurement process can be quickly restarted.


Conclusions: Laser R-Test (LRT)

CatalogQR Code

Measurement items and functions

1. Backlash: linear and rotary axes2. Geometric errors of rotary axis3. High dynamic contouring error4. Thermal drift and spindle runout5. Quick check of angular positioning

Current Collaboration researches

Now NFU has collaborated with Prof. MASAOMITSUTSUMI (TUAT), and Prof. SOICHI IBARAKI(HU) for new functions development and the casestudy of Japanese machine tools; therefore, eachgroup has borrowed one set of LRT and alsofinished the formal training courses.


Conclusions: Laser R-Test (LRT)

CatalogQR Code

ContactTaiwan

Chia-Ming Hsu許家銘 , Chief Engineer of Laser R-test,


Tel:+886-5-6315934, Email: [email protected]

Dr. Masaomi TSUTSUMI, Professor Emeritus,

Tokyo University of Agriculture and Technology

Mobile:+81-90-5586-0683, Email: [email protected]

With OPC UA communication protocol, SMEcan provide production line information, andestablish application services of managementand control, and improving the efficiency andyield rate of production line


Conclusions: Smart Machine Engine (SME)

CatalogQR Code

System features and functions1. Connects all equipments of a smart factory

(e.g., machine tool , robot, PLC equipment ).2. Supports various platform and third-party

software.3. Dynamic scheduling and tool management.4. Supports 90% controllers (in Taiwan).

ContactTung-Hsing Lucas Hsieh謝東興 , Chief Engineer of SME,


Tel:+886-5-6315402 , Email: [email protected]


Patents

1. 發明專利: “一種多軸工具機量測裝置” ，大陸發明專利ZL 2010 1 0259753.6，專利權始日20130904，發明人：覺文郁、劉建宏、徐東暉、許家銘。

2. 發明專利: “ ASSEMBLY FOR A MULTI-AXIS MACHINE TOOL多軸工具機量測裝置” ，日本發明專利5038481，專利權始日20120713，發明人：覺文郁、劉建宏、徐東暉、許家銘。

3. 發明專利: “ ASSEMBLY FOR A MULTI-AXIS MACHINE TOOL多軸工具機量測裝置” ，歐盟發明專利EP 2340914 B1，專利權始日20121226，發明人：覺文郁、劉建宏、徐東暉、許家銘。

4. 發明專利：“DETECTING ASSEMBLY FOR A MULTI-AXIS MACHINE TOOL多軸工具機量測裝置”，美國專利局專利核定發明第US 7,852,478 B1號，專利權始日20101214，發明人：覺文郁、劉建宏、徐東暉、許家銘。

5. 發明專利: “Method of Detecting a dynamic path of a five-axis machine tool and assembly for the same -五軸工具機動態路徑檢測方法及其裝置”，美國專利局專利核定發明US 8,116,902 B2，專利權始日20120214，發明人：劉建宏、覺文郁、李羿宗。

6. 發明專利: “多軸工具機量測裝置”，中華民國經濟部智慧財產局專利核定發明第I378843號，發明人：覺文郁、劉建宏、徐東暉、許家銘。

7. 發明專利名稱: “工具機旋轉軸定位精度檢測裝置與方法”，中華民國經濟部智慧財產局專利核定發明第I592252號，發明人：覺文郁、謝東賢、陳明亮、謝東興。

8. 發明專利: “機器人校正系統與方法”，中華民國經濟部智慧財產局專利核定發明第I579123號，發明人：覺文郁、謝東賢、李在原、陳俊仁、謝東興、吳家鴻。

9. 新型專利: “機器人校正系統”，中華民國經濟部智慧財產局專利核定新型第M530737號，發明人：覺文郁、謝東賢、李在原、陳俊仁、謝東興、吳家鴻。

10. 新型專利: “光學式轉軸多自由度誤差檢測裝置”，中華民國經濟部智慧財產局專利核定新型第M545243號，發明人：覺文郁、謝東賢、許仲良、許家銘、張祐維、黃森億、謝東興。

Reference


Reference Journal Papers

Theses

1. W. Y. Jywe* and C. J. Chen, 2005, “The development of a high-speed spindle measurement system using a laser diode and a quadrants sensor”, International Journal of Machine Tools & Manufacture, Vol. 45, pp. 1162-1170.

2. W. Y. Jywe*, T. H. Hsu and C. H. Liu, 2012, “Non-Bar, an Optical Calibration System for Five-axis CNC Machine Tools”, International Journal of Machine Tools & Manufacture, Vol. 59, pp.16-23.

1. Chia-Ming Hsu, 2011, “Development of an Optical Measurement System for Five-axis CNC Machine Tools”, Master Thesis.

2. Mu-Cheng Ji, 2012, “Development and Application of Measurement Technologies for Five-axis CNC Machine Tools using NON-BAR Measurement System”, Master Thesis.

3. Yu-Wei Chang, 2013, “Detecting Dynamic Parameter Setting Technology and Application for Five-Axis CNC Machine Tools using NON-BAR Measurement System”, Master Thesis.

4. Shu-Yu Yang, 2014, “Development and Application of an Interface for the NON-BAR Measurement System”, Master Thesis.

5. Ching-Ying Chiu, 2015, “Development of a simple optical constant-angular positioning measurement system for rotary axis”, Master Thesis.

6. Ming-Liang Chen, 2016, “Development of an automatic error measurement and compensation system with machine-to-machine connection capabilities for multi-axis machine tools”, Master Thesis.

7. Zai-Yuan Li, 2016, “Image-type Intelligent Calibration and Compensation System to Five-axis Machine Tools”, Master Thesis.

Wen-Yuh JyweChair Professor / PresidentNational Formosa University

[email protected]


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