ZDMP Experimentation Facility

The ZDMP Experimentation facility (based in Tampere University, Finland) provides a physical environment to study and freely experiment ZDMP components (zComponents) and applications (zApps) to ascertain their functionalities and capability to ensure zero-defects in manufacturing.

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Winners

​The experimentation facility is made of up industrial equipment, machines, and devices, which include:

  • FESTO MPS Assembly Line.

  • EMCO Milling Machine.

  • Portable Air Pressure Box.

  • In addition:

  • Mobile Industrial Robot (MiR100).

  • Omron Quattro Robot (4-axis parallel Robot).

  • ABB Yumi (Dual-Arm) Collaborative Robot.

  • Industrial Communication Devices (Fieldbuses) for implementing different industrial protocols such as EtherCAT, CANopen, Profibus, and Interbus as well as Safety buses.

Full FASTory Assembly Line:

ZDMP Experimentation Facility.jpg
ZDMP Experimentation facility

It is an industrial environment which focuses on factory automation systems, intelligent manufacturing systems, and human-robot collaboration - thereby supporting the industry 4.0 concept. It will facilitate the testing, validation, and integration of ZDMP components and applications. It will provide ZDMP stakeholders, both project beneficiaries and subcall partners, the opportunity to validate ZDMP component requirements and provide solutions to integration problems at an early stage before applying them on the actual industrial use cases.

Technical support will be offered to its users as well as training for experimenters regarding the use of the equipment both during proposal stage and to winners using the facility.

FESTO MPS (Modular Production System) Assembly Line

The FESTO MPS Assembly Line demonstrates the assembly of piston-cylinder assembly in an industrial environment. It consists of different stations for mechanical testing, mechanical processing, robotized distribution and assembly, buffering, automated storage, and retrieval system which are all connected by a conveyor line. The stations are equipped with Siemens ET200sp (CPU1500) controllers and linked by Siemens industrial Ethernet network. It is connected to 11 PC workstations enabled for developing complete automation solutions (SCADA-PLC-Simulation).

Features:

8 workstations equipped with ET200sp controllers, 2 Mitsubishi robots (with extended I/O modules), 1 CNC machine, Pneumatic network for actuator control, sensors (proximity, light, capacitive, inductive, optical etc), Safety perimeter radars by PILZ and PROFINET.

Logical controller:

Siemens ET200sp distributed I/O modules.

Networking:

Siemens industrial Ethernet network.

Supported technologies:

MQTT, OPCUA

Monitorable parameters:

Equipment status, maintenance information, power & energy levels.

Relevance to ZDMP use cases:

Automotive and Electronics use cases.

Example supported ZDMP Components and zApps:

Data Acquisition component, Monitoring & Alerting component, Message Bus component, zVisualManager, zPowerManager, zAutomaticCall etc.

FESTO MPS Assembly Line (Main view).jpg
FESTO MPS Assembly Line (Main view)
FESTO MPS Assembly Line (Top view).jpg
FESTO MPS Assembly Line (Top view)
FESTO Line Connections.jpg
FESTO Line connection to PC workstations for developing SCADA-PLC Simulation
FESTO MPS Line Workpiece Assembly.jpg
FESTO MPS Line Workpiece Assembly
FASTory Assembly Line

The FASTory Assembly Line highlights the collaboration between robots and machines. It mimics phone assembly operation by drawing (yes, you read that right) different phone models. It consists of 10 workstations each with a robot that can draw the main components (frame, screen and keyboard with different colours and shapes) of three models of a mobile phone on a sheet of paper carried by a pallet. This combination results in the production of 729 variants (i.e., 9 different screens * 9 different keyboards * 9 different frames). The product flow in the assembly line is made possible by a conveyor. The FASTory assembly line makes use of air pressure to actuate the track selector in the conveyor and the end effector in the robots. In addition, each workstation has a bypass conveyor that enables the transit of pallets to the next available workstation while the robot is in use. Each workstation is equipped with web-service enabled Remote Terminal Units (RTUs) for subscribing to predefined events on each workstation (such as sensor changes or robot status). The RTUs are implemented using the INICO S1000 controller and is based on Service-Oriented Architecture (SOA).

Features:

10 workstations, 10 robots (including Omron, ABB, Kuka, Sony and FANUC robots), pneumatic network for actuator control, different sensors, conveyor (main and bypass), energy meters.

Logical controller:

INICO S1000 controller.

Networking:

Ethernet network.

Supported technologies:

REST

Monitorable parameters:

Equipment (Robot and conveyor) status, maintenance information, power & energy levels, production start & end times, production order status.

Relevance to ZDMP use cases:

Automotive and Electronics use cases.

Example supported ZDMP Components and zApps:

Data Acquisition component, Monitoring & Alerting component, Message Bus component, zVisualManager, zPowerManager, zAutomaticCall etc.

FASTory Assembly Line (Main view).jpg
FASTory Assembly Line (Main view)
Sony Robot and Pallet on FASTory Assembl
Sony Robot and Pallet on FASTory Assembl
Sony Robot and Pallet on FASTory Assembly Line
Robots Layout on FASTory Assembly Line.j
Robots Layout on FASTory Assembly Line
EMCO Milling machine

The EMCO Concept Mill 105 is a compact CNC desktop milling machine with a space for 10 tools on the spindle to perform different operations on workpieces like milling, thread milling, tapping, drilling etc. It consists of high-resolution axis motors and is integrated with safety technology. The spindle rotation is both clockwise and anti-clockwise and the milling machine work area is fully covered thereby ensuring safety (i.e., protection against chips) during its operation. The EMCO milling machine is also integrated into Flexible Manufacturing Systems (FMS) through the robotics interface which controls peripheral equipment (eg automatic door) and connects the milling machine to other machines and devices. The EMCO milling machine is connected to a MELFA RV3SDB robot (6 DOF) and buffer station via RIA box. The robot is responsible for loading workpieces and unloading finished products from the milling machine. It is suitable for the teaching of manufacturing technologies and its control is connected via PC, on which the interchangeable WinNC is installed. The milling machine is equipped with EMCO WINCC software solution for interchangeable control. It is also equipped with a portable machine operating panel for operating the machine through hardware, which consists of axis buttons, feed override switch, mode switch etc.

Features:

Tool turret with 10 stations (for tool change), Automatic door, Pneumatic unit for automatic door and pneumatic tailstock connection, high-resolution axis motors, portable machine operating panel.

Software/control:

EMCO WINCC (for interchangeable control)

Monitorable parameters:

Tool health, tool failures, tool change time out, central oil system level, air pressure, spindle speed, feed stop, equipment status, power & energy levels.

Relevance to ZDMP use cases:

Machine Tool use case.

Example supported ZDMP Components and zApps:

Data Acquisition component, Monitoring & Alerting component, Message Bus component, zMachineMonitor, zMachineAnalytics.

EMCO Milling Machine (Front View).jpg
EMCO Milling Machine (Front View)
EMCO Milling Machine with the Loading an
EMCO Milling machine with the loading and unloading Robot
Portable Air Pressure Box

Energy losses due to air leakage in pneumatic control systems is a common occurrence in factories across Europe. The portable air pressure box developed in FAST-Lab in Tampere University is utilized for measuring the air pressure supplied to the entire FASTory and FESTO assembly lines. It provides information about air pressure drop resulting from any air leakage in the assembly lines. The air pressure box is also equipped with an INCO S1000 controller, which can be used to program device logic.

Logical controller:

INICO S1000 controller.

Supported technologies:

REST

Monitorable parameters:

Air pressure (energy consumption)

Relevance to ZDMP use cases:

Automotive and Electronics use cases.

Example supported ZDMP Components and zApps:

Data Acquisition component, Monitoring & Alerting component, zPowerManager etc.

Portable Air Pressure Box.jpg

Portable Air Pressure Box