Report
Teaser, summary, work performed and final results
Periodic Reporting for period 1 - iPROCELL (Commercial validation of iPROCELL: a novel modular assembly practice)
Teaser
The iPROCELL project reaches markets with currently unmet needs. This market is for the production and assembly of large consumer products such as passenger vehicles, white goods and furniture that is being produced on an economic scale that fits between manual manufacture and...
Summary
The iPROCELL project reaches markets with currently unmet needs. This market is for the production and assembly of large consumer products such as passenger vehicles, white goods and furniture that is being produced on an economic scale that fits between manual manufacture and full mass production line assembly methods. In our primary target market of Electric Vehicles (EV’s), where small batches of units are produced, neither manual or mass production methods are cost effective.
iPROCELL is a fully automated final assembly cell, with 3 autonomous robots situated around a central build location; it has a footprint is 12 times smaller than traditional production lines. Our novel modular construction practice provides a cost effective, fully automated, final assembly solution that brings benefits to both the consumer and the supplier:
• Space and cost saving to manufacturers with our small footprint enabling decentralised production practices
• Decentralisation builds new regional supply chains and boosts local economies
• Time and cost saving for consumers, from decentralisation and our lean manufacturing model
• Increased customisation available to customers at no additional time or cost with flexible manufacturing
• Increased factory effectiveness with production of successively different products
• High quality production, with SOA robotics and IoT maintained product warranties
With our patented modular construction approach there are no direct competitors to iPROCELL. Our solution is designed to work alongside existing mass production lines, complementing the customer options available. Some development has been seen by BMW, Tesla etc in integrating robotic production lines for flexible production but these are limited to existing practice. Volkswagen (VW) are currently rolling out their modular platform but not focussing on altering automation production practices.
The principle project objectives are to: 1) develop a suitable gripper system and 3D camera system, 2) integrate the sensor and image technology; 4) gain the necessary legal framework and standards accreditation; 5) develop the subsystems; 5) build the demonstrator unit; 6) complete testing and trials and complete trials; 7) complete design for manufacture of the product to a commercial mass market; 8) industrialise the technology for volume production and 9) complete commercialisation activity. This future-oriented production control and logistics binds all process steps from the module production at the suppliers to automated final assembly to enable us to successfully commercialise iPROCELL.
Work performed
WORK PACKAGE 1 – PROJECT MANAGEMENT
• Regular consortium meetings
• Patent granted
• Website creation
WORK PACKAGE 2 – OVERALL DESIGN AND ASSEMBLY SYSTEM DESIGN
• Defined the framework conditions for the design of the system
• Verified the overall concept of the control strategy
• Determined safety controls
• Developed a pallet transportation system
WORK PACKAGE 3 – CONTROL TECHNOLOGIES AND INTERACTIONS
• Identified the movement parameters for the control modules
• Implemented simulations and visualisations of the robot simulation programme
• Defined the control architecture
• Developed a precise plan for production
WORK PACKAGE 4 – DEVELOP GRIPPER TECHNOLOGY
• Selected the most suitable RFID smart tags and sensors
• Developed the gripper hardware
• Designed the gripper sensors
• Developed a tool change-over system
WORK PACKAGE 5 – INTEGRATION OF SENSORS AND IMAGE PROCESSING
• Developed an analysis software tool
• Selection and design of the 3D image processing systems
• Developed a safety concept - virtual “protective fenceâ€
WORK PACKAGE 6 – DEFINITION OF INDUSTRIAL APPLICATIONS AND CAPABILITIES
• Developed safety systems for human-machine interactions
• Produced work regulations documentation
• Gained certifications
WORK PACKAGE 7 – PRE-DEVELOPMENT OF THE PARTIAL SYSTEMS
• Developed and tested the subsystem AGV (Automatically Guided Vehicle)
WORK PACKAGE 8 – DEVELOP THE DEMONSTRATOR MODEL
• Produced technical drawings of the final assembly stations.
• Planned the production phase; update the bill of materials
WORK PACKAGE 11 – DESIGN FOR MANUFACTURE AND COMMERCIALISATION
• Demonstrated at several high-profile events: Hannover Messe 2018 and NORTEC 2018
Final results
The iPROCELL solutions offers reduced material wastage compared to manual practices as a result of the precision offered. But further to this, iPROCELL offers the flexibility of manual manufacturing to produce customised products on demand but at a scaled down production rate and efficiency equivalent to mass manufacturing.
The modular assembly process of iPROCELL is particularly suited for small series production and has the flexibility to make batch sizes of one and up with equal economies of scale. Thus, with iPROCELL it becomes possible to manufacture products in line with market requirements and on demand. The cell consists of several robots working together in the assembly process and performing machine-to-machine-interaction using the future standards of industrial digitisation to produce high quality products with manufacturer warranties.
Most importantly, iPROCELL is a cost-effective production solution that bridges the SOA technological gap between manual vehicle production and mass production lines. For those companies currently operating as a manual manufacturer but are looking to expand, iPROCELL offers a solution to meet their production needs at a cost-efficient price. Similarly, for those companies currently using mass production lines, that are looking to offer their end users higher levels of variation and customisation in their products, iPROCELL offers a cost-effective alternative production method.
Confirmed by work carried out during our Phase 1 Feasibility Study, it is our informed belief that iPROCELL is a completely new production process. The innovative production method, based on assembly of modules, enables savings in logistics and production costs. With iPROCELL:
• customised products can be made at decentralised locations for in line with the current market.
• different products or product variations can be produced successively.
• new supply chain models strengthen regional added-value
Advantages of iPROCELL:
• iPROCELL offers the customer a highly flexible production cell that can produce small series and individualised products with low investment costs.
• A special characteristic of iPROCELL is the adaptable gripper system with which the robots can take up a huge number of the assemblies to be added and positioned. This increases applicability, reduces clock rates and minimises production costs. Separate sales of our gripper system will provide additional income for IBG.
• Local regions and businesses will profit from successful market entry of iPROCELL. For logistic reasons the decentralised manufacturing will lead to a greater integration of regional suppliers. Transport savings associated with compact packing of modules and shorter distances will save energy and lower the CO2 output.
Added value to potential customers
• With iPROCELL it will be possible to produce and to offer small series of complicated products, e.g. electric vehicles, for prices in line with market requirements. This will benefit both customers and IBG.
• With iPROCELL the customer gets high flexibility with successive production of different products
Website & more info
More info: http://ibg-i.de/iprocell/.