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Smart Components within Smart
Production Processes and
Environments - SCoPE
Methodist University of Piracicaba
Laboratory for Computer Application in Design and
Manufacturing (SCPM)
Prof. Dr.-Ing. Klaus Schützer
Darmstadt University of Technology
Department of Computer Integrated Design (DiK)
Prof. Dr.-Ing. Reiner Anderl
Page 2
International Cooperation
Polytechnic School -
University of São Paulo
Laboratory of Innovation
Management (LGI)
Prof. Dr. Eduardo S. Zancul
Darmstadt University of
Technology
Department of Computer
Integrated Design (DiK)
Prof. Dr.-Ing. Reiner Anderl
1st Phase: 01/08/2014 – 31/07/2016
2nd Phase: to submitted in December2015
Methodist University of
Piracicaba
Laboratory for Computer
Application in Design and
Manufacturing (SCPM)
Prof. Dr.-Ing. Klaus Schützer
Prof. Dr. Alexandre Simon
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From product to component data model
Component data model
Formal scheme for component
creation to component recycling
Component-specific view
Distinction:
• Concrete dimensions
instead of tolerances
• Individual production plans
Product data model
Formal scheme for product idea
to the product use
Representation of product data
Existing implementations e.g.:
• Native format
• STEP
• JT
Product data model Physical product Component data model
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Integrated product data model
Product data model
Product data
management
system
Production
planning
Representation of product model
Harmonization of product data models
and interfaces for exchange
Formal scheme
form product idea to the product use
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Component Data Model Semantic product memory
Limited Data storage
Physically attached to
components
Aggregation of
component-specific data
Data intentionally created
during life cycle from
creation over use to
recycling or disposal
RFID(~32.000 Bytes)
QR code(2.953 Bytes)
Data Matrix(1.556 Bytes)
Product memory
+
Physical product
HeaderTable of
contentsBlock 1 … Block n
ID, Meta, Text, File, URL, References, …
Source: Broy, M. et all, 2010
Binary data format Semantic Memory
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Smart Components with Smart Production Processes and
Environments – SCoPE
Integrated Component Data Model
Formal scheme from product creation
to component recycling
Product Data Model
+
Component Data Model
Product data model Physical product Component data model
Product & production
developmentProduction
Component data modelIntegration to engineering processes
Focus: Integration to production planning
Front-loading of virtual engineering processes
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Integrated component data model
• Customer data
• Shipping conditions
• Users
• Groups
• Roles
• Views
• Manufacturing data
• Measured data
• Testing data
• Assembly data
• Requirements
• System model
• Material specifications
Identification & Specification data Production data
Order-related dataRights management data
Core model• Administrative Information
• Organizational Information
• Geometric representation
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Components become information carriers
Integration of products and modern internet based
information and communication technologies
Transformation of physical component to
information carriers
Component-specific data (Physical properties,
Customizations, Manufacturing history and
Purpose)
Application in recent cyber-physical production
systems
Components actively control manufacturing and
assembly procedures
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Product Data Model vs. Component Data Model
Produktpräsentation
ICDM
Privileges
Production
Specifications
OrderCore
<<import>>
<<import>>
<<import>>
<<import>>
All components
Component 4711
Component 0815
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Use case – Traceability of components
Information and communication technologies
Integrated data storage
Internet communication interfaces
Individual logic
Product data model Component data modelPhysical productwith semantic product memory
+
Smart components
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Use case – Traceability of components
Band Saw
KASTO SBA A2Milling Machine
EMCO Mill 250
Milling Center
DMC 50H
Setup time & Costs
Machine availability
Tool wear and life
Worker identification
Energy consummation
…
Assembly Station
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Use case: Smart component within complex assembly
Smart parts “find” suitable counterparts.
Otherwise rejected parts can be used. Total number of rejects is reduced.
✗ ✗Nominal fit in
assembly
✓Oversized
inner diameter
Oversized
outer diameter
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Use case: Smart production planning
Nowadays:
Component-driven production
planning
Production planned for customer-
tailored components
Component individual structure
Individual production processes,
sequences and plans
Formerly:
Order-driven production planning
Production globally planned
for whole product series
Global structure for product series
Released production plans for
controllable production processes
(sequence, resource, material)
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Use case: Smart production planning – Partial models
Partial models of the integrated component data model
1. Product manufacturing information:• Process plan
• Desired tolerance fields
2. Numerical control (NC) code:
• Planned tolerance fields
3. On-line data from shop floor:• Tool wear of milling machines
• Producible tolerance fields
4. Physical products with product memory:
• Produced dimensions
N0010 G54 G90 G71 G94
N0020 T01 M06
N0030 S4000 M03 F2000
N0040 M08
N0050 G00 X-30 Y0 Z5
N0060 G01 Z0
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Use case: Smart production planning
Efficiency target: Maximize tool wear exploitation
Approach: Schedule milling operations
appropriate to tolerance fields
1. Consider interdependencies between planned (virtual),
producible and produced (physical) tolerance fields
2. Create individual, customer-tailored manufacturing plans:
• Processes with narrow tolerance fields before wider tolerance fields
• Component-individual routing within the production
More use cases available:
Optimization or higher degree of capacity utilization
Improve availability and condition of machine resources
Reduce warehouse stock and intermediate stores
N0010 G54 G90 G71 G94
N0020 T01 M06
N0030 S4000 M03 F2000
N0040 M08
N0050 G00 X-30 Y0 Z5
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Thank you for your kind attention!
The presented work is being conducted with support from:
SCoPE
Smart Components within Smart
Production Processes and Environments
Prof. Dr.-Ing. Klaus Schützer