Technology Roadmap - SMART

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TechnologyRoadmap1st ofFebruary,2018

Contents1Introduction . 32Technology Roadmap structure. 43Industrial challenges, gaps, barriers and bottlenecks to be solved. 53.13.1.1Grand Challenge . 53.1.2Gaps, Barriers and Bottlenecks to be solved . 53.2Grand Challenge . 73.2.2Gaps, Barriers and Bottlenecks to be solved . 7Consumer Goods Sector . 93.3.1Grand Challenge . 93.3.2Gaps, Barriers and Bottlenecks to be solved . 93.4Capital Goods Sector . 113.4.1Grand Challenge . 113.4.2Gaps, Barriers and Bottlenecks to be solved . 113.55Automotive Sector . 73.2.13.34Aeronautic Sector . 5Railway Sector . 133.5.1Grand Challenge . 133.5.2Gaps, Barriers and Bottlenecks to be solved . 13Enabling Technologies . 154.1Material Processing Technologies . 154.2Mechatronic Technologies and Systems. 164.3Flexible, Adaptive and Collaborative Robotics . 174.4Information and communication technologies. 184.5Production Technologies . 19Research and innovation domains . 215.1Advanced Manufacturing Processes . 215.2Intelligent and Adaptive Manufacturing Systems . 225.3Digital, Virtual and Efficient Companies. 225.4Person-Machine Collaboration . 235.5Sustainable Manufacturing . 235.6Customer-based Manufacturing . 24SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com2

1 IntroductionWith its approximately 20 industrial sectors, Manufacturing forms the backbone of the economyof many countries of the European Union. Manufacturing is a vital area, whose role is increasinglyseen as fundamental towards European recovery and sustainable growth. It is a relevant KeyEnabling Technology for the current shift towards a ‘Competitive Sustainable Globalisation’,addressing grand Socio-Economic and Environmental challenges of our times.Advanced Manufacturing Technologies are perceived as a key player in the new industrialrevolution. For example, 3D additive manufacturing permits the production of much smallerbatches, making low cost customised production possible and opening new market niches forinnovative SMEs. Tomorrow’s companies are expected to use highly efficient processes in termsof energy and raw materials use; they will incorporate recycled and renewable source-basedmaterials, designing products aimed at reuse and disassembly, and promote the adoption ofsustainable business models based on circular economies, industrial symbiosis and value chainintegration.Furthermore, the new possibilities brought by advances in information technologies and theirapplication in industry, mean that Information Technologies and Knowledge become closelyinterwoven with industrial equipment and processes, converging towards virtual manufacturing,- or immersive reality. Concepts like the Internet of Things, Cyberphysical Systems or CloudComputing, are now commonly used in the design and development of new products andservices. This will bring important challenges to people involved in manufacturing, which willrequire an adequate working environment, new tools and lifelong training specifically devised foradvanced manufacturing factories.This technology roadmap illustrates the technology areas and developments that are needed totake a big step in the competitiveness of the manufacturing industry in Europe.The final Technology Roadmap will be the result of a reflection process carried out within theframework of SMART: Advanced Manufacturing Eureka Cluster, leaded by important players fromthe European industry and completed with the contribution from academy and Researchorganisations. The roadmap will provide the vision of strategic challenges identified in severalhigh impact industrial sectors: Aeronautic, Automotive, Consumer Goods, Capital Good andRailway in which the technologies and new solutions developed within the cluster projects shallbe mainly applied.Our aim is for this to be a living document that grows and improves with the viewpoint of relevantagents and entities from the different industrial sectors considered.SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com3

2 Technology Roadmap structureSMART Technology Roadmap is developed based on three building blocks:1. The industrial challenges that manufacturing companies face, with the gaps, barriers andbottlenecks that they need to overcome in order to improve their competitiveness(Chapter 4)2. The enabling technologies and trends that are pushing forward the developmentcapabilities, which will be basic to develop innovative solutions (Chapter 5)3. Finally, based on the two previous blocks, 6 research and innovation domains are definedto address the industrial challenges, and that are further divided in specific topics.(Chapter 6)4SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com

3 Industrial challenges, gaps, barriers and bottlenecks tobe solved3.1 Aeronautic Sector3.1.1Grand ChallengeThe main challenges of the aeronautical sector in advanced manufacturing focus on importantreduction of recurrent costs and lead time. An ambitious evolution needs to be addressed inaspects such as integrated design and manufacturing development processes, composite andmetal material processing, simulation and automation, digital transformation, monitoring andcontrol, flexible manufacturing and assembly, and supply chain integration.3.1.23.1.2.1Gaps, Barriers and Bottlenecks to be solvedSHORT TERMDEVELOPMENT OF NEW LOW COST/HIGH VOLUMEN PROCESSES:New process systems allowing low cost manufacturing of structural aeronautical parts at higherproduction rates is the main objective at short term. Search into enablers for this kind ofadvanced processes allowing also a flexible or modular manufacturing is part of the focus, suchare intelligent or flexible tools or ancillaries. Furthermore, the costs associated with assembly ofaeronautical elements has a high impact on the aircraft final cost and so a greater integration ofcomponents at elementary part level is a necessity.Along this line, technological developments related to more accurate and automated humancentered assemblies, integrating light automation and robots is a challenge.MONITORING AND CONTROLSafety associated with the product in the aeronautical industry is intrinsic to the existence of thebusiness. The quality of the parts is a requirement for the entire production and safety elementshave priority over any other consideration. Current process control means and non-destructiveinspection of the manufactured elements is costly and time consumingNew generation design and production processes must combine specifics sectorialcharacteristics. To this end, active monitoring and full integration of the validation and verificationSMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com5

systems throughout the product operating life is a need. Process parameter measurement in realtime techniques, output predictability with control and action over inputs need to be developed.Technologies that increase component s safety and reliability range from more powerful andreliable simulation tools, on-line monitoring and control techniques and the integration ofstructural monitoring systems during the operating life of the aeronautical product, includingmeasurements incorporated into automated and non-automated production, to mention themost relevant examples.3.1.2.2LONG-TERMCONCURRENT DESIGN AND MANUFACTURINGThe weight of an aircraft structure is an improvement target in terms of the reduction ofemissions, consumptions and increasing the market share of all manufacturers. The need for allthose companies that form part of the value chain is to develop technologies that generate lessweight is a direct consequence. New materials under research (composites, metals, ceramics,multi-laminates, nano-composites, etc.) or their combination will demand the development ofnew production processes. Concurrent development of materials and processes is a must.On the other hand, decreasing development times and increasing technologies maturity levels,before entering series production, is one of the main objectives for the aeronautical industry.Improved demonstration capabilities and simulation techniques and adequate training will beessential.COMPLETE DIGITAL TRANSFORMATIONEven when partial integration of new ICT tools, as for instance improving the information givento operators to assure quick first time right execution is a short-term technology development,the complete digital transformation towards a virtual factory (and a virtual aircraft as a first step)is a long-term objective: To eliminate the risks generated by training personnel to undertake the assignedoperations To have detailed information about the situation of production processes in real time,shortening the gap between production and management Optimizing preparation, downtime and tool changeover times Processes simulation (for improving ergonomics, etc.) Including active monitoring and control of processes End to end data backbone Intelligent operations coordination, including supply chain Tooling and parts controlSMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com6

3.2 Automotive Sector3.2.1Grand ChallengeThe automotive sector landscape is rapidly changing, and must address the following globalchallenges: higher market and cost pressure, rise of product complexity by new mobility patternsand connectivity, and increasingly restrictive emissions and fuel-consumption requirements.In terms of manufacturing, this implies developing systems capable of processing new advancedmaterials, as well as walking the path towards flexible, digital and sustainable production.3.2.23.2.2.1Gaps, Barriers and Bottlenecks to be solvedSHORT-TERMPARTS INSPECTION AND MEASURING IN MANUFACTURING PROCESSESIn the automotive industry, strict product tolerances require comprehensive in-process controlof components and final product’s quality. To effectively correct deviations and guarantee thatfinal product meets required tolerances, control must happen in real time. Artificial vision systemsplay a definite role in these control mechanisms and must allow image capture and analysis inreal time.In the automotive industry, continuous inspection will provide the data for a completelyautomated control, which will considerably increase efficiency and reduce the level of rejects,number of faulty parts and costs derived from inadequate behaviour in service. Apart fromdeciding if a part or assembled system meets required specifications, the inspection system mustdifferentiate the faults, without any mistake, communicating their position and analysing possiblesources of error, in order to be able to adopt the appropriate corrective measures. On the otherhand, and with respect to functional behaviour, the surface inspection will undertake anincreasingly important role.DECREASE OF ENERGY CONSUMPTION BY PRODUCED UNITThis is an approach whose aim is to reduce the amount of energy consumed by implementingmeasures and investments at technological and resource management level, with the objectiveof achieving a reduction in the energy used by each unit produced.This focuses on getting the production plants to reach maximum energy efficiency. Thus,management systems aimed at reducing consumptions and emissions of CO2, automated energymanagement systems, and cogeneration and reutilization of waste for energy generation, will beused.SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com7

Achieving this objective will require performing an analysis and simulation of the raw materialand energy flow in each one of the production chain processes, which will contribute tominimising the environmental impact and focusing optimisation efforts on the processes andequipment that really have an impact on total energy consumption.3.2.2.2LONG-TERMDEVELOPMENT OF IMAGE PROCESSING SYSTEM TO DETECT MODEL DIVERSITIESThe complexity of the production systems that derives from the diversity required by customersand by market demands, requires an increase in the inspection task. Being able to introducedetection systems and diversity confirmation into the different chain phases, requires fast andlow cost processing solutions. These systems must also work in unfavourable environments:Electromagnetic fields, variable lighting, variable temperatures, etc.The coexistence of photonics and robotics with advanced manufacturing processes in industrialenvironments, will permit monitoring large series of parts and parameters in reasonably shortperiods of time. The solutions of image processing and sensor systems are also cross-cutting foralmost all sectors of industry, thus ensuring a high impact. They are also essential to achieve anincrease in production ratios in the automotive sector.AUTONOMOUS ROBOT OPERATIONAL NETWORKS WITH EMBEDDED INTELLIGENCE8The objective is based on developing a functional network comprised of flexible robots that canoperate in changing environments to respond flexibly to new situations, and have advancedcommunication interfaces, such as voice recognition and visual recognition systems.Adapting to the operator’s environment and adopting the necessary safety responses, whilstmaintaining flexibility and the auto-adjustment of operational parameters, will optimisecollaborative work, enabling more complex, dangerous or non-ergonomic processes to beaddressed.The development of integrated sensors, actuators and fast computing systems will ensure aneffective co-existence between robots and workers. Repeatability and auto-calibration, as well aseasy programming of robot activities, are key points for the evolution of robotics towards therequired production environments, and their smooth incorporation into existing manufacturinglines.SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com

3.3 Consumer Goods Sector3.3.1Grand ChallengeThe challenges of the consumer goods sector related to advanced manufacturing technologiesfocus on the following points: high rate production of customised products, incorporation ofintelligence into the product chain by means of information management, implementation ofuser-guided creativity and innovation, integration of new materials and nano-intelligence, andgreen production chains for sustainable products.3.3.23.3.2.1Gaps, Barriers and Bottlenecks to be solvedSHORT-TERMMATERIALS AND TECHNOLOGIES FOR DIGITAL MANUFACTURE OF COMPONENTS(EG: AUTOMATIC 3D PRINTING)The eruption of additive manufacturing technologies into the field of prototyping is giving way tonew forms of manufacturing, which, in the mid-term, must tend to integrate different systemsand offer the possibility of working with practically any materials/structures.In order to be able to work at relatively reasonable costs in functional products, further toconceptual models, an effort must be made to adapt/modify materials for their use in additivemanufacturing systems, either syntherising, FMD or others, offering the end user the possibilityof using practically any type of material or combination of materials.Another possibility is the functionalization of materials used in additive manufacturing for specialapplications, increasing their possibilities of use. The development of builders that permit a localimprovement in deposition precision or modification of the properties of the same material indifferent product areas is also an important field.ADVANCED VALUE CHAIN INTEGRATION SOFTWARE, INCLUDING DEVELOPMENT OFCOMPETITIVE INTELLIGENCE SYSTEMS BASED ON KNOWLEDGE OF THE MARKETAND OF THE CUSTOMERBased on the possibility of companies integrated in the value chain exchanging data, the challengelies in offering total integration from design to the point of sale, so that it is possible to generatefeedback with a view to redesigning or readapting products/processes.In this context, it is essential to capture knowledge from the market and from the customer. Thisis achieved by watching over the environment, which results in different processes: sourcemanagement (search and update), tool management (definition and adaptation), methodologySMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com9

definition (routines, procedures, formats), and the categorisation, protection and disseminationof information.This information contains the explicit knowledge of the environment available to the company,and which, when it reaches its addressees, becomes tacit knowledge, that is, knowledge that canpromote programmes and projects that adapt and improve production processes.3.3.2.2LONG -TERMDESIGN SYSTEMS THAT INCORPORATE GEOMETRY, MATERIALS, THEIR TECHN ICALCHARACTERISTICS AND COSTS. NEW CAD SYSTEM GENERATION. DESIGN FORMANUFACTURING.Design systems in the consumer goods sector are essential. At the present time CAD systems onlycontemplate geometry but they are far from providing an integral solution to the process thatgoes from the design to the manufacture of the product.The future generation of design systems will be based on the concept of design formanufacturing, because of which, the CAD system will not just be taking into account the productgeometry, but also the materials that make them up, the costs entailed, the technicalcharacteristics that influence the manufacture, and the parameters of the machines/systems theywill be manufactured with. Simulations of the product/process and of the human being-productbehaviour will be obtained. A step further would even give rise to the integration of marketingdecisions. With this future generation of design systems, the long-awaited Business Accelerationwill be reached.ADAPTABLE, NETWORKED AND KNOWLEDGE -BASED DIGITAL MANUFACTURINGDEVELOPMENTFactories of the future with a great variety of sophisticated consumer goods must offer a flexibleand rapid production capacity, with controlled variability thanks to advanced automation. Thisguarantees energy-efficient, reliable and cost-effective production. Assuring optimal execution“the first time”, by improving the information given to operators relating to the manufacture orthrough other means, is a way of improving the current productivity. That is why the integrationof new ICT tools is a technology development line to be deployed with different approaches andobjectives: To eliminate the risks generated by training personnel to undertake the assignedoperationsTo have detailed information about the situation of production processes in real time,shortening the gap between production and managementOptimizing preparation, downtime and tool changeover timesImproving ergonomicsFurthermore, exchanging data between companies in the value chain must permit totalinteroperability between both design and manufacturing systems. Collaboration and connectivitywill provide an enormous amount of data, so those companies that carry out their analyses in realSMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com10

time will have a competitive advantage. Beyond integrated sensors and systems, the tendency isto interact in two directions with real objects and global scale systems, through a variety ofapplication fields and interlocutors. This will be done in a safe manner and thus the Internet ofThings will be constructed.3.4 Capital Goods Sector3.4.1Grand ChallengeThe Capital Goods sector faces 3 major challenges with respect to manufacturing; reduce the leadtime from design to delivery with higher requirements of safety sustainability and zero defects,produce sustainably green manufacturing systems and assure the connectivity of the machinesinto highly complex cyber-physical manufacturing systems.3.4.23.4.2.1Gaps, Barriers and Bottlenecks to be solvedSHORT-TERMGREEN MANUFACTURING SYSTEMSThe impact that companies have on the environment must be reduced and natural resourcesprotected, more so in the European Union, which is deficient in natural sources of criticalmaterials. The efficiency of capital goods not only affects their contribution to global warming orthe emission of CO2, but also the reduction of cost factors such as energy and raw material.The management of the material and energy flow throughout the lifecycle means monitoring andoptimising consumption in each and every one of the phases of the manufacturing chain.Concepts around manufacturing with zero defects undoubtedly contribute to a reduction in thenumber of faulty parts, and consequently, to maximising energy efficiency, the use of equipmentand of material resources.SERVICE DEVELOPMENT FOR INTELLIGENT MANUFACTURINGWe are witnessing the emergence of a new era in production technologies, where machines andprocesses are increasingly influenced by information and communication technologies (ICTs).Cyber-Physical Systems (CPS) are collaborative computational elements that control physicalentities, such as machine tools, assembly lines or other types. These CPS can interact andintercommunicate to optimise different aspects of the manufacturing process. But they are alsoextremely useful to provide operators with strategic information, at the right time and in afriendly manner. This will enable more effective decision-making and will contribute to thedissemination of knowledge at company level.SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com11

The manufacturers of machine tools demand the development of multi-variable modelling andsimulation tools, with capacity to use advanced cloud computing, eliminating the need forlicences and with real time access to equipment behavioural data through integrated sensorsystems.3.4.2.2LONG-TERMNEW FUNCTIONALITIES BASED ON SURFACE MODIFICATIONThe increase in precision of manufacturing systems and the growing proximity betweenmanufacturing and the micro/meso-scale, provide product designers with the capacity to affordenhanced functionalities based on surface modification, micro-texturing or advanced coatings.These functionalization can be achieved based on physical phenomena (additive manufacturing,micro-machining laser technologies, micro-milling, water jet, additive manufacturing, 3D printingor PVD coating (or based on chemical phenomena (coating by CVD, sol-gel, etc.).Apart from developing robust processes from the viewpoint of their industrial scale-up,equipment must be developed that permit applying these surface modifications at macrodimensional level, in many different products and industrial sectors, in a time-efficient andeconomical manner.Efficient functionalization must be accompanied by the development of the necessary simulationmodels, foreseeing the behaviour that the system is going to have, once functionalised, or withthe capacity to modify the process parameters according to the effect sought.SYMBIOTIC HUMAN-ROBOT INTERACTIONSymbiotic and immersive collaboration between robots and humans in production environmentswill undoubtedly lead to the development of more efficient and flexible manufacturingcompanies. However, the aspects of cooperation, overlapping and safety in the industrialenvironment, as well as the advanced computational and sensorial processing algorithms havenot been sufficiently developed to guarantee safe and seamless cooperation at manufacturingplants.Manufacturing companies focus on unifying the work space of human beings and robots, but thisrequires the robot design to be safe and trustworthy, with integrated control and intelligence. Toachieve the necessary capacities for the robots to be able to interact and cooperate with humans,self-learning strategies will be decisive.SMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com12

3.53.5.1Railway SectorGrand ChallengeThe main challenges of the railway sector in the field of advanced manufacturing are in line withthe objective of achieving intelligent, safe, faster, efficient and sustainable transport, and theyfocus on 5 areas: integration of modular systems, interoperability of equipment, efficiency in theuse of resources, processing of lighter materials and use of ICTs and electronics to add intelligenceto the processes.3.5.23.5.2.1Gaps, Barriers and Bottlenecks to be solvedSHORT-TERMPRODUCTION AIMED AT SUSTAINABLE TRANSPORTImproving the efficiency of railway capital goods (rolling stock and infrastructure systems) is abasic objective that leads not only to a decrease in energy consumption per passenger unit ortransported ton, but it also contributes to improving competitiveness of railway transport andimproving the carbon footprint. Building on the fact that this mode of transport generally bringslower carbon footprint, a faster railway transport system will result in mode change andpassenger and cargo migration towards rail, hence again lowering the carbon footprint caused ofother, less efficient, modes of transport.The integration of the lifecycle and recyclability variables from the design, production, operationand maintenance phases of railway material favour investments in control and optimisation ofenergy consumption throughout the value chain.The incorporation of lighter materials is a consequence of the need to reduce energyconsumption. Passenger comfort is an important conditioning factor when designing rolling stock,and vibrations are a field where manufacturers must seek alternatives with less repercussion andabsorption of tension and stress.The challenges mentioned in the field of materials have a direct impact on production means.PRODUCTION AIMED AT INTELLIGENT TRANSPORTThe tendency towards repetitive manufacturing and modularisation in the railway sector leads toproduction management environments that are new for this industry: the potential of big dataoffers enormous possibilities, considering the product lifecycle.Cyberphysical systems (CPS) or electronic sensors for instrumentation and control of operationsare devices that will be integrated into production processes. They will also be increasinglyintegrated into the actual railway capital goods (rolling and fixed stock), so that they will facilitateSMARTPaseo Mikeletegi, 59 Parque Científico y Tecnológico de GipuzkoaSan Sebastián, 20009Tel. 943 309 009 Fax 943 309 191info@smarteureka.com www.smarteureka.com13

functionalities and improve the actual railway transport operation management. Up to the levelof the highest grade of transport automation – driverless operation.Bearing in mind that the average life of rolling stock is around 40 years, the analysis and cost oflifecycle mean that simulation and m

2 Technology Roadmap structure SMART Technology Roadmap is developed based on three building blocks: 1. The industrial challenges that manufacturing companies face, with the gaps, barriers and bottlenecks that they need to overcome in order to improve their competitiveness (Chapter 4) 2.

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