CREATING A SMART ENVIRONMENT

FOR THE ADVANCED MANUFACTURING

Implementation of Pilot line with example Cassamobile Project

Dr. Udo Gommel, Tanja Meyer, Christian Seifarth

INNOVATION AS A PREREQUIS ITE FOR THE KNOWLEDGE AGE
Buchares t, 07/09/2016

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FRAUNHOFER INSTITUTE FOR MANUFACTURING
ENGINEERING AND AUTOMATION – IPA

in cooperation with the Institutes EEP, IFF and ISW

of the University of Stuttgart

Future is our product

Sustainable. Personalized. Smart.

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The Fraunhofer-Gesellschaft
Europe`s largest “applied-research” organization

 Fraunhofer-Gesellschaft:
Rostock
 66 institutes and
Bremen Berlin
research facilities
Hannover Dresden
in Germany
Dortmund
 24.000 employees Darmstadt
 €2 billion budget Saarbrücken
S tuttgart
Karlsruhe München
 Fraunhofer IPA: Freiburg
 14 departments
 6 business units
 490 employees
 € 60.3 million operational budget

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Fraunhofer Gesellschaft
– daily business: two sides of a coin

Motivation 1 Motivation 2

66 Institutes each with A single organization with

different “Institute cultures” one m is s ion

More than 250 business fields Applied research

and core competencies as profession

Excellent research Strong orientation for application

Institutional and project Revenues from contract res earch

funding

Management/rules of a public Entrepreneurial spirit

institution to be lived

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IPAs manufacturing topics of today and tomorrow
Trends that influence our work

Manufacturing organization Production proces s es

 Service engineering and hybrid business  Additive manufacturing
models for decentralized production and
 Machining fiber and composite materials
complex value systems
 Processing functional and nano materials
 Adaptable manufacturing systems
 Coating technologies and materials
 Highly-efficient energy usage and energy
management  Flexible machines and handling systems
 Resource and quality management

Inform ation and com m unication technology , autom ation

 Data-based and knowledge-based systems
and processes
 Cyber-physical manufacturing systems,  Robotics and assistive systems
decentralized automation solutions  Laboratory automation
 Production of / with biological systems
Source: BMBF-Foresight-Zyklus II, search phase 2012-2014, 3rd interim result; selected research and technology perspectives 2030

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Dep. »Ultraclean technologies and micromanufacturing«
What makes us special?

 Independent
 30 years of expertise
 Unique infrastructure
 Research for industry,
especially in close cooperation
 Guidline activities and
standardization
(national & international)

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Ultraclean technologies and micromanufacturing
Facts and figures

Pharmaceutical,
medical and
biotechnology
Semiconductor
technology and
 46 scientists microelectronics

 44 research assistants
Cleanliness technology

EXPERTIS ES
 80 patents Precision assembly and
application technologies
Automotive
 € 7 million engineering
Digital printing (2D/3D)
Design and control of clean
turnover p.a. manufacturing environments

Machinery
and plant
engineering
Photovoltaics

Information and Microsystems

communication
technology

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Ultraclean technologies and micromanufacturing
Our customers

ABB Ltd • BMW AG • Bosch Rexroth AG • Carl Zeiss Gruppe • Charité –

Universitätsmedizin Berlin • Continental AG • centrotherm photovoltaics
AG • Daimler AG • DENSO Corporation • European Space Agency • Festo
AG • Infineon Technologies AG • KMS Automation GmbH • KUKA AG •
Leybold Optics GmbH • Marabu GmbH & Co. KG • M+W Group • OC
Oerlikon Corporation AG • OHB-System AG • Pelikan Hardcopy
Production AG • PEPperPRINT GmbH • Retina Implant AG • ROTH +
WEBER GmbH • Samsung Group • Schiller Automation GmbH & Co. KG •
SCHUNK GmbH & Co.KG • Siltronic AG • Sovello GmbH • SÜSS MicroTec
AG • Volkswagen AG • ZF Friedrichshafen AG

 Cleanroom planners and production s uppliers

 Manufacturers of miniaturized and contamination critical products
 Device and equipment manufacturers in the field of clean, micro and
nanomanufacturing as well as digital printing and additive manufacturing
 Developer and controller of manufacturing systems (s oft- and hardw are)

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Ultraclean technologies and micromanufacturing
Infrastructure

CLEANLINESS PRECISION ASSEMBLY DIGITAL PRINTING DESIGN AND CONTROL

TECHNOLOGY AND APPLICATION TECHNOLOGIES OF CLEAN PRODUCTION
TECHNOLOGY (2D/3D) FACILITIES

 Cleanroom laboratories  Micro assembly laboratory  Digital printing laboratory  Handling laboratory
ISO 1-7 (2D/3D)
 Biosafety lab level 2

 Particle detection  High-precision assembly  Inkjet-test stations for  Various manipulator

 2D and 3D microscopes and positioning system
 Conditioning cabinet  dispensing and application
technology for low up to
 Material test bench
highly viscous mediums
 NanoPhotonics, CNC,
 measurement and testing
ellipsometer, contact angle
technology for surface
 2D and 3D cleaning analysis and detemination
equipments
of adhessive forces
(CO2, laser, plasma, ultra
 Surface modification
and mega sonic)
techniques
functional coatings
 Electrophotography
equipment for rigid
substrates
 3D printer based on inkjet,
dispensing and DLP®
technology for:
 System control:
 Ceramics
 Micro system technology
 Biomedicine
 High-speed camera
 Simulation:
PlantSimulation, SimuLink
 System integration:
SEMI, OPC-UA, I4.0,
in-house developments
ABB, Beckhoff, B&R,
Kuka, Siemens

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Understanding of Pilot Lines

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Comments from the European Commission
regarding Pilots

Excerpt from Industrial Technologies Conference, Amsterdam, 24/06/16

- Open Pilot Facilities as a European Resource for Innovation & New Business

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CassaMobile Project

 Example of European funding and financing support scheme

 Example for a regional pilot line

 Existing pilot facility

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How it all began

 Call for „Plug & Produce“ production systems for industrial and
consumer goods, which provide …
 high flex ibility with respect to products , production
v olum es , process & production env ironm ents
 easy reconfigurability , using intelligent,
s elf-adaptiv e proces s m odules

 Such „Plug & Produce“systems shall produce products …

 maximally adapted to cus tom er’s needs at – or close to –
the required location, and at the right tim e

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CassaMobile motivation
Challenges for European Industry

Productions systems are influenced by

rapidly changing customer and production requirements

influence on

Products Volume Processes Environment

Market need for adaptable production

systems

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General concept of CassaMobile

 The CassaMobile concept aims at providing a…

 local, flex ible and environmentally friendly
production of highly cus tom ized parts

 The CassaMobile production system is based on a…

 truly m odular architecture
(modular manufacturing system using
a pool of process modules)
 along with the need of
m inim al v olum e / s pace (ISO-Container)

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CassaMobile Goals

Production Proces s Hum an Machine Technical

S y s tem Modules Interface Container
 Truly m odular  Comprehensive  Eas y -to us e  20` ISO-Container
architecture pool of proces s system for direct  Comprehensive
 S m all footprint m odules user interaction cleanlines s
production  Process modules  Software for concept
machine allow direct production  Validated
 Plug & Produce cus tom ized of custom s y s tem
control system products designed (e.G. GMP),
 Additive products if required
 Quality control
and tracing manufacturing
system  CNC-milling

S y s tem for flex ible, local and cus tom ized production

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Potential application fields:
after earthquakes; e.g. Nepal, Chile (2015) and Amatrice (2016)

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Easy and fast help using CassaMobile

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Use-case 1: Bone drill guide

 A knee drill guide (with model)

 Patient specific medical device
 Provides a unique fit on the bone
 Based on a patient scan
 During surgery,
guides the surgeons’ drill and saw

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Use-case 2: Orthotics

 Externally applied devices used to correct the structural and

functional characteristics of the neuromuscular and skeletal system
 FO: Foot Orthotics
 AFO: Ankle Foot Orthotics

 Capabilities
 Additive Manufacturing and milling
 Digital Data Acquisition

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Use-case 3: Customized gripper

 customized
gripper
fingers

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CassaMobile use cases

The “Generic Product Demonstrator“

combines all features and requirements
of all three use cases!

The demonstrator features:

 Free-formed surfaces
 Surface for fine milling
 Part assembly (pressing)
 Sensor integration into cavity
(embedding)
 Cleaning and sterilisation of sensitive
surfaces
 Unique object ID
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Process Module Development from
Concept to Container

Process Module Development

Additiv e As s em bly Cleaning &

CNC Milling
Manufacturin S terilis ation
Module Module
g Module Modules
System Concept

Establishing Detailed CAD

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Cleanroom concept

FFU‘s above each module

FFU above
module

AC unit

 design keeps the manufacturing modules as

clean as required
 return air to be mixed with conditioned fresh air
 optimized airflow
 ISO 7 acc. to ISO 14644-1,
Air flow
(and better inside the process area)
 customized solutions for other pot. applications Conditioned air (T; rH)

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Cleanroom measurement points

Measurement points series 1

Measurement points series 2

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 Cleanroom measurement results

Particle concentration s eries 1

Particle count/m ³
Particle concentration s eries 2
Particle s ize µm
Particle count/m ³

Container m eas urem ent res ults

Particle s ize µm
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Self-adaptive control system
– recombination of
different process modules
Module Pool

Module 1 Module 2 Module 3 Module 4 Module 5

Use case 1 Use case 2

requirements requirements

Reconfiguration to meet the use case requirements

 Costs, quality, production speed, efficiency
 Reconfiguration requires adaption of all software components of the CassaMobile
container

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HMI on the CassaMobile context

HMI
CAM
file

CAD
file

Module 1 Main
Module 2 Control
Module n (MC)

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What it looks like

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Highlights

 A prototy pe of the container factory s y s tem has been des igned and s et-up
 System can be easily transported and set up
 System can be configured according to changing requirements
 Enclos ed unit allow s the control of proces s conditions
 Temperature and humidity are controlled by air conditioning
 Particulate contamination controlled by filtering system
 Modular Com ponents S y s tem
 Modules can be exchanged and those changes are reflected on the system all
the way up to the HMI
 Quick integration with a variety of hardware
 Flex ible Workflow creation and ex ecution

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Facts & figures

 Project Type: Demonstration-oriented project

 Duration: 01.09.2013 - 31.08.2016 (3 years)
 Total budget: 8,748,000 €
 Funding: 5,650,000 €
 Number of partners: 11
 Total efforts: 663
 Total number of people working for CassaMobile: ≈ 53
 Total number of reports generated: ≈ 37
 Total num ber of publications : 33
 Total num ber of ex ploitable res ults : 20

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Impressions from Concept to Container

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Needs for specific actions and instruments at regional,
national and EU-level

S pecific actions and aw arenes s ris ing tow ards needs for:
 Owners of Pilot facilities and -lines and their technical/ operational is s ues
 Better understanding of opportunities for pilot line owner and users
 Finance and funding providers
 Policy decision makers  Innovation Policy
 Provision of expensive technical infrastructure for SMEs to use as a 'tes t bed‘

Inv olv ing dev elopm ent of:

 Cooperation m echanis m s across borders
 Open netw ork of finance prov iders (private, institutional and public)
 Innov ation hubs , training and networking across Europe
 Bus ines s creation support instruments

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Conclusions addressing issues such as

 Prom oting the bus ines s offers and orientation of technology owners, users and
investors across value chains.
 Identify ing the need and existing mechanisms for supporting pilot business
planning and execution.
 Cooperation between European regions;
 Discuss Manufuture role in collaboration with national/regional and European level
initiatives;
 Manufacturing is the Key Econom ic area to create high adding Value
by transformation of material and energy to products.
 Dev elopm ent and tes ting of the lates t m ethods in cooperative production
lines

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Fraunhofer IPA
Your contact partner

Care-O-bot® 4

Future is our product

Sustainable. Personalized. Smart.

Giving you a competitive edge

Sustainable. Flexible. Economical.

Dr. Udo Gommel

Head of Department
Ultraclean Technology and Micromanufacturing www.ipa.fraunhofer.de/en.html

Phone +49 711 970-1633

Udo.Gommel@ipa.fraunhofer.de

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