Work progress and achievements

Invitation - Expert Workshop: "Factory of the Future Clusters"

Written by Markus Wabner and Alexander Schumann, Fraunhofer IWU

Thursday, 07 Jan 2016

We would like to invite you to the Expert Workshop "Factory of the Future Clusters" on February 16th in Brussels.

The Expert Workshop will not only cover general information about the FOCUS Project but also 10 international industrial experts from Japan, USA, Canada, Australia, the Netherlands and Italy will hold presentations and give detailed insights into the five Clusters "Zero Defect Manufactoring", "Robotics", "High Precision Manufactoring", "Clean Factory" and "Maintenance". Moreover, there will be a panel discussion with Experts, Cluster Leaders and Moderators. The workshop will take place on February 16th at the Crowne Plaza Hotel in Brussels. For further information, workshop schedule and registration please find the official brochure on the link below.

Expert Workshop Brochure

Expert Workshop

Review: Demonstration Seminar of FP7 Project iMain - A Novel Support System For Predictive Maintenance in Forming

Written by Markus Wabner and Alexander Schumann, Fraunhofer IWU

Wednesday, 08 Dec 2015

With great satisfaction we are looking back at our Demonstration Seminar of the FP7 Project iMAIN – A NOVEL SUPPORT SYSTEM FOR PREDICTIVE MAINTENANCE IN FORMING in June 2015 in Velenje, Slovenia.

It was a very interesting and fruitful event which gave detailed insights into the latest cloud based innovations in Condition Monitoring. Participants also used the opportunity to take part in discussions and live demonstrations with end users, machine builders and research experts. Starting with a warm welcome and an overall introduction into the event schedule, the iMAIN Project and the involved participants were presented. Next, a closer look was given at the iMAIN solutions which was followed by an astonishing demonstration of the iMAIN eMaintenance Cloud. After a delicious lunch, participants were able to get a vivid idea about the iMAIN accomplishments through a live demonstration at the Gorenje Toolshop. Afterwards a revealing discussion about selected topics took place. We are very happy about the great feedback and the success of the seminar and want to thank all participants and especially our partner GorenjeGroup for hosting this delightful event and for giving us the opportunity to demonstrate iMAIN.

Gorenje seminar photo

Demonstration Seminar of FP7 Project iMain - A Novel Support System For Predictive Maintenance in Forming

Written by Markus Wabner, Fraunhofer IWU

Wednesday, 02 Jun 2015

We would like to invite you to our Demonstration Seminar of the FP7 Project iMAIN – A NOVEL SUPPORT SYSTEM FOR PREDICTIVE MAINTENANCE IN FORMING on Tuesday, 30th June 2015 at Velenje, Slovenia. Enjoy the latest cloud based innovations in Condition Monitoring and take part in discussions and live demonstrations with end users, machine builders and research experts. Accommodation will be available the night before the seminar. Please register via e-mail until the 15th of June.

gorenje-LOGO

Virtual Sensor Technology successfully implemented

Written by Robert Tehel and Markus Wabner, Fraunhofer IWU

Wednesday, 03 Dec 2014

Using virtual sensors for minimizing the number of real sensors in strain measurement

The frame components of forming presses are highly stressed parts. Since the application of real sensors in every critical zone is not affordable and not efficiently enough, all the necessary data for the estimation of remaining useful lifetime are acquired now with a minimal amount of real sensors.

news1

Figure: Strain measurement in forming machines with virtual sensors

iMAIN is installing two condition monitoring systems in automotive industry

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN is installing two condition monitoring systems in automotive press machines

iMAIN installed condition monitoring system in Switzerland

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN installed a condition monitoring system at a press machine manufacturer in Switzerland

Cyber Physical Production Systems: Maintenance within Industrie 4.0

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN Solution for Intelligent Maintenance in Production

Germany's Industrie 4.0 initiative – a part of the Hightech Strategy of Germany's Government – aims to develop networked industrial machinery with built-in intelligence based on smart self-monitoring functions. This will also enable a new quality in maintenance based on a proper and safe IT infrastructure, which has to provide the necessary flexibility regarding permanently changing requirements in terms of information channels, data mining algorithms and added-value services.

news1

Figure: iMAIN maintenance support system within Industry 4.0

iMAIN will present on AMA Congress 2015

Written by Martin Riedel, imc Meßsysteme GmbH

Thursday, 27 Nov 2014

iMAIN project: Advanced Condition Monitoring Concepts Allow Predictive Maintenance - Incorporating Virtual Sensor Simulation and Cloud Based Decision Making

AMA Congress 2015, SENSOR 2015 - IRS2 2015, 19. - 21. Mai 2015, Nürnberg

iMAIN at EuroMold 2014

Written by Markus Wabner, Fraunhofer IWU

Thursday, 13 Nov 2014

Advanced Condition Monitoring of Forming Presses

November 25 – 28, 2014, FRANKFURT / MAIN, GERMANY

Hall/booth: 11.0/C66

Fraunhofer-Institut für Werkzeugzeugmaschinen und Umformtechnik IWU

iMAIN Demonstration meeting at GORENJE

Written by Markus Wabner, Fraunhofer IWU

Thursday, 13 Nov 2014

iMAIN has demonstrated condition monitoring and cloud access

November 4 - 7, 2014, VELENJE, SLOVENIA

iMAIN project has hold a meeting at the end user GORENJE AG in Velenje, Slovenia to demonstrate the project progress to all partners and to EC. During the successful meeting the main focus was on the demonstration of the test installation of the Embedded Data Acquisition System (ECEM) at a LITOSTROJ RAVNE forming press.

news1

Figure: Installed sensory in the Gorenje forming press

iMAIN at EUROBLECH 2014

Written by Petra Petra Janežič, Gorenje Orodjarna, d.o.o.

Monday, 18 Aug 2014

iMAIN and Gorenje Orodjarna at EUROBLECH 2014

October 21 – 25, 2014, HANNOVER, GERMANY

Gorenje Orodjarna, d.o.o.

iMAIN presentation at MPMM 2014

Written by Gerardo Glorioso, Advantics and Markus Wabner, Fraunhofer IWU

Monday, 18 Aug 2014

Maintenance Support Wireless System for Ram of Forming Presses

September 4 - 5, 2014, COIMBRA, PORTUGAL: The iMAIN partner ADVANTIC – a high-tech Spanish SME which has an important background in information and communication technologies specialized in the field of wireless sensor networks (WSN) – has presented “Maintenance Support Wireless System for Ram of Forming Presses” in the E-MAINTENANCE Session at the Maintenance Performance Measurement and Management Conference 2014 (MPMM 2014).

EuroMaintenance 2014

Written by Markus Wabner, Fraunhofer IWU

Thu, 3 Apr 2014 10:20

In May 2014 a common workshop with similar EU projects (Power-OM and SUPREME) has been organized at the EuroMaintenance 2014, Helsinki, Finland. Enclosed to this, there is a common panel discussion.

Definition of different tasks finished

Written by Markus Wabner, Fraunhofer IWU

Fri, 14 Feb 2014 14:15

System architecture/ layered architecture finished

The task aims the decomposition of the overall system in self-reliant and parallel developing modules. Due to amount of data (frequency and volume) a layered architecture with data acquisition-, processing- and visualization modules has been deemed the most appropriate solution, as described in D2.1. The needed input and output quantities as well as the necessary functions and classes have been described for each module. All functions and classes have been formulated in an abstract way in case of supplements. Based on the algorithms necessary processing power and memory requirements of the ECEM devices have been dimensioned.

Definition of system architecture for eMaintenance cloud finished

In this task the system architecture for an e-maintenance cloud based on the state-of-the-art has been developed. Beginning with the definition of system architecture for development of eMaintenance cloud, detailed analysis has been done to define the system architecture and how the services will interact within the architecture. The eMaintenance cloud architecture is based on service-oriented multi-layer approach. Service-Oriented Architecture (SOA) can be implemented by using web services with a set of XML-based open standards, such as WSDL, SOAP, and UDDI.

Definition of software architecture for eMaintenance cloud finished

The aim of this task is to provide an overarching definition of software architecture that can be utilized in the development process of e-maintenance cloud. First software development platforms have been selected. The overall eMaintenance Cloud (eMC) architecture is based on a service-oriented multi-layer approach. Services inherent provided in the cloud are specialized for various purposed, e.g. data storage, data analysis, communication, integration, authentication, data transition and data visualization. The eMC cloud helps to create and manage new physical and virtual environments efficiently by providing functionalities and resources that are available on the physical servers. The eMC cloud will provide a virtualized hardware platform, based on VM Ware technologies in combination with Microsoft Server infrastructure. Thus, eMC will provide various services hosted in the virtual environment within the physical layer. In addition, to access services of eMC, remote desktop connection will be used by the users to connect to remote computer from another location using either a PC or Macintosh computer.

Definition of hardware architecture for eMaintenance cloud finished

The aim of this task was to define the necessary hardware architecture required for the operation of the eMaintenance Cloud and all of the related components. As outlined in D3.1, the system consist of a DA component in the form of an embedded system that is fast and deals with the raw data streams and a companion system running on generic PC hardware for the actual storage of the data as well as the configuration of its DA counterpart. The PC-counterpart will also provide interfaces for additional data sources like audio/video streams or the wireless devices.

Smart cMODEL development finished

Written by Markus Wabner, Fraunhofer IWU

Tue, 31 Dec 2013 11:20

To use the Complex cMODEL as embedded virtual condition sensors on real press equipment and to get just-in-time information about influences of varying or unforeseen loads and disturbances on the condition of the equipment, a reduced Smart cMODEL has been derived from the Complex cMODEL. The former preferred approach to use a reduced FE model that has to be adapted by neural networks to the practical properties of the presses has been substituted by a much more efficient approach – the weighted linear combinations. The reasons for this have been a) the training of neural networks is very time-consuming and b) a number of load cycles will not be stored in the data base. In this WP could be shown that the selected approach is very promising.

Customisable eMODEL development finished

Written by Markus Wabner, Fraunhofer IWU

Tue, 31 Dec 2013 11:20

As introduced earlier (problems in direct measurement of energy-relevant parameters), the option of predictive energy consumption analyses in production environments is very interesting. For this, a user-friendly Customisable eMODEL has been derived from Complex eMODEL. It allows the virtual testing of different (future) load scenarios (e.g. derived for example by offline process simulation or from former real loads, stored from data history) via an user interface. The Customizable eMODEL software is introduced and documented in D1.6.

Condition model development finished

Written by Markus Wabner, Fraunhofer IWU

Mon, 30 Sep 2013 11:20

Especially on large components like frames, failure-critical zones are not exactly known and are strongly dependent on actual loads. Thus, optimal condition monitoring is limited due to sensor placement. To solve this problem and to limit the number of real sensors, virtual sensors will be used in the ECEM system (WP2&3). For it, complex stress FEM simulation models for the detection of failure-critical zones (Complex cMODEL) have been developed in this WP.

Condition model development finished

Written by Markus Wabner, Fraunhofer IWU

Mon, 30 Sep 2013 11:20

Especially on large components like frames, failure-critical zones are not exactly known and are strongly dependent on actual loads. Thus, optimal condition monitoring is limited due to sensor placement. To solve this problem and to limit the number of real sensors, virtual sensors will be used in the ECEM system (WP2&3). For it, complex stress FEM simulation models for the detection of failure-critical zones (Complex cMODEL) have been developed in this WP.

Energy model development finished

Written by Markus Wabner, Fraunhofer IWU

Mon, 30 Sep 2013 11:15

To get information about influences of components condition (friction, wear, process,…) as well as organisation (part dependent loads) on the energy consumption of the equipment, complex energy consumption models including drives, lossy components (bearing friction) and ancillary units have been developed in this task. This has been done with Matlab/SIMULINK. Based on this, influence analyses has been performed to get knowledge about energy-relevant components (energy-relevant system identification). Based on this information, energetic part of ECEM strategy will be developed in WP3. The Complex eMODEL is described in D1.3.

Embedded simulation environment development (onSIM Module) finished

Written by Markus Wabner, Fraunhofer IWU

Mon, 30 Sep 2013 11:20

For the virtual condition sensors (Smart cMODEL) an embedded real-time simulation IT infrastructure (onSIM module) in hard- and software has been developed (ECEM DA). This is going ahead the proposal, where a “just-in-time” simulation was planned (e.g. for every forming cycle). For it, the system has to be analysed considering general aspects like in- and outputs, number and size of data or data storage. For service life prediction (SSLP) a second system is available (ECEM-PC). Both systems belong to the ECEM system.

Dissemination

Written by Markus Wabner, Fraunhofer IWU

Sun, 30 Jun 2013 11:20

Dissemination is responsible for internal and external communication about the project and the results to the public, the scientific community, the manufacturing industry and potential business users. The overall objective with the planned dissemination activities is to ensure that value is created within the targeted dissemination groups and that the Commission funding lead to further advancements in society and industry. Dissemination is considered as a continuous task.

Failure mechanisms & prediction approaches

Written by Markus Wabner, Fraunhofer IWU

Sun, 31 Mar 2013 11:20

With the focus on service life prediction of frame components, physical failure mechanisms have been analyzed systematically, based on state of the art. Mathematical description methods have been specified for the failure mechanisms identified above.

Project website

Written by Markus Wabner, Fraunhofer IWU

Sun, 31 Mar 2013 11:20

The “iMAIN” project website started: www.imain-project.eu

Impact Workshop of the Factories of the Future PPP at Brussels/Belgium

Written by Markus Wabner, Fraunhofer IWU

Mon/Tue, 11./12. Mar 2013 08:20

iMAIN is involved in cluster activities with other projects to find synergies especially in dissemination activities. In March 2013 the projects coordinators joint a clustering meeting in Brussels (PPP Impact Workshop) as a starting point for future clustering activities. In May 2014 a common workshop with similar EU projects (Power-OM and SUPREME) has been organized at the EuroMaintenance 2014, Helsinki, Finland. Enclosed to this, there is a common panel discussion.

Problem identification finished

Written by Markus Wabner, Fraunhofer IWU

Mon, 31. Dec 2013 14:20

The production equipment regarding critical components, which are relevant for maintenance, has been analyzed. A complete overview for both presses is given in D1.1. The appearance of typical and unusual loads and disturbances has been analyzed, as well as the availability of control-inherent data (e.g. motor current for process force calculation) of the considered equipment. Concerning the press forces it could be shown that especially eccentric press forces led to varying problems concerning accuracy and high mechanical stresses. Concerning the other maintenance-relevant components, especially vibrations will lead to problems in gear lubricant. That will be monitored in future.

Industry 4.0: A Novel Decision Support System for Intelligent Maintenance in Forming Presses

iMain project is an FP7 project funded by EU (ID 314304). The project has a duration of 36 months and has started on 1st of September 2012. For the success of the project 8 partners from 4 European countries work together.

Industrie_4.0

Our objective is to develop a novel and advanced concept with a practical verified solution for an information-based predictive maintenance system which will include:

  • An embedded condition & energy monitoring system, which will nearly operate personal self-sufficient
  • A smart service life prediction system, that will complement the ECEM system through a number of virtual sensors
  • A novel e-maintenance strategy using cloud e-maintenance

News

Invitation - Expert Workshop: "Factory of the Future Clusters"

Written by Markus Wabner and Alexander Schumann, Fraunhofer IWU

Thursday, 07 Jan 2016

We would like to invite you to the Expert Workshop "Factory of the Future Clusters" on February 16th in Brussels.

The Expert Workshop will not only cover general information about the FOCUS Project but also 10 international industrial experts from Japan, USA, Canada, Australia, the Netherlands and Italy will hold presentations and give detailed insights into the five Clusters "Zero Defect Manufactoring", "Robotics", "High Precision Manufactoring", "Clean Factory" and "Maintenance". Moreover, there will be a panel discussion with Experts, Cluster Leaders and Moderators. The workshop will take place on February 16th at the Crowne Plaza Hotel in Brussels. For further information, workshop schedule and registration please find the official brochure on the link below.

Expert Workshop Brochure

Expert Workshop

Review: Demonstration Seminar of FP7 Project iMain - A Novel Support System For Predictive Maintenance in Forming

Written by Markus Wabner and Alexander Schumann, Fraunhofer IWU

Wednesday, 08 Dec 2015

With great satisfaction we are looking back at our Demonstration Seminar of the FP7 Project iMAIN – A NOVEL SUPPORT SYSTEM FOR PREDICTIVE MAINTENANCE IN FORMING in June 2015 in Velenje, Slovenia.

It was a very interesting and fruitful event which gave detailed insights into the latest cloud based innovations in Condition Monitoring. Participants also used the opportunity to take part in discussions and live demonstrations with end users, machine builders and research experts. Starting with a warm welcome and an overall introduction into the event schedule, the iMAIN Project and the involved participants were presented. Next, a closer look was given at the iMAIN solutions which was followed by an astonishing demonstration of the iMAIN eMaintenance Cloud. After a delicious lunch, participants were able to get a vivid idea about the iMAIN accomplishments through a live demonstration at the Gorenje Toolshop. Afterwards a revealing discussion about selected topics took place. We are very happy about the great feedback and the success of the seminar and want to thank all participants and especially our partner GorenjeGroup for hosting this delightful event and for giving us the opportunity to demonstrate iMAIN.

Gorenje seminar photo

International Event: Demonstration Seminar of FP7 Project iMain - A Novel Support System For Predictive Maintenance in Forming

Written by Markus Wabner, Fraunhofer IWU

Tuesday, 02 Jun 2015

We would like to invite you to our Demonstration Seminar of the FP7 Project iMAIN – A NOVEL SUPPORT SYSTEM FOR PREDICTIVE MAINTENANCE IN FORMING on Tuesday, 30th June 2015 at Velenje, Slovenia. Enjoy the latest cloud based innovations in Condition Monitoring and take part in discussions and live demonstrations with end users, machine builders and research experts. Accommodation will be available the night before the seminar. Please register via e-mail until the 15th of June.

gorenje-LOGO

iMAIN will be present at Hannover Messe 13 – 17 April 2015

Written by Markus Wabner, Fraunhofer IWU

Wednesday, 04 Feb 2015

iMAIN will be present at Hannover Messe 13 – 17 April 2015 on Fraunhofer Group for Production”, Hall 17, Stand F14.

Virtual Sensor Technology successfully implemented

Written by Robert Tehel and Markus Wabner, Fraunhofer IWU

Wednesday, 03 Dec 2014

Using virtual sensors for minimizing the number of real sensors in strain measurement

The frame components of forming presses are highly stressed parts. Since the application of real sensors in every critical zone is not affordable and not efficiently enough, all the necessary data for the estimation of remaining useful lifetime are acquired now with a minimal amount of real sensors.

news1

Figure: Strain measurement in forming machines with virtual sensors

iMAIN is installing two condition monitoring systems in automotive industry

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN is installing two condition monitoring systems in automotive press machines

iMAIN installed condition monitoring system in Switzerland

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN installed a condition monitoring system at a press machine manufacturer in Switzerland

Cyber Physical Production Systems: Maintenance within Industrie 4.0

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN Solution for Intelligent Maintenance in Production

Germany's Industrie 4.0 initiative – a part of the Hightech Strategy of Germany's Government – aims to develop networked industrial machinery with built-in intelligence based on smart self-monitoring functions. This will also enable a new quality in maintenance based on a proper and safe IT infrastructure, which has to provide the necessary flexibility regarding permanently changing requirements in terms of information channels, data mining algorithms and added-value services.

news1

Figure: iMAIN maintenance support system within Industry 4.0

iMAIN will present on AMA Congress 2015

Written by Martin Riedel, imc Meßsysteme GmbH

Thursday, 27 Nov 2014

iMAIN project: Advanced Condition Monitoring Concepts Allow Predictive Maintenance - Incorporating Virtual Sensor Simulation and Cloud Based Decision Making

AMA Congress 2015, SENSOR 2015 - IRS2 2015, 19. - 21. Mai 2015, Nürnberg

iMAIN at EuroMold 2014

Written by Markus Wabner, Fraunhofer IWU

Thursday, 13 Nov 2014

Advanced Condition Monitoring of Forming Presses

November 25 – 28, 2014, FRANKFURT / MAIN, GERMANY

Hall/booth: 11.0/C66

Fraunhofer-Institut für Werkzeugzeugmaschinen und Umformtechnik IWU

iMAIN Demonstration meeting at GORENJE

Written by Markus Wabner, Fraunhofer IWU

Thursday, 13 Nov 2014

iMAIN has demonstrated condition monitoring and cloud access

November 4 - 7, 2014, VELENJE, SLOVENIA

iMAIN project has hold a meeting at the end user GORENJE AG in Velenje, Slovenia to demonstrate the project progress to all partners and to EC. During the successful meeting the main focus was on the demonstration of the test installation of the Embedded Data Acquisition System (ECEM) at a LITOSTROJ RAVNE forming press.

news1

Figure: Installed sensory in the Gorenje forming press

iMAIN at EUROBLECH 2014

Written by Petra Petra Janežič, Gorenje Orodjarna, d.o.o.

Monday, 18 Aug 2014

iMAIN and Gorenje Orodjarna at EUROBLECH 2014

October 21 – 25, 2014, HANNOVER, GERMANY

Gorenje Orodjarna, d.o.o.

iMAIN presentation at MPMM 2014

Written by Gerardo Glorioso, Advantics and Markus Wabner, Fraunhofer IWU

Monday, 18 Aug 2014

Maintenance Support Wireless System for Ram of Forming Presses

September 4 - 5, 2014, COIMBRA, PORTUGAL: The iMAIN partner ADVANTIC – a high-tech Spanish SME which has an important background in information and communication technologies specialized in the field of wireless sensor networks (WSN) – has presented “Maintenance Support Wireless System for Ram of Forming Presses” in the E-MAINTENANCE Session at the Maintenance Performance Measurement and Management Conference 2014 (MPMM 2014).

Project partners

    • Fraunhofer IWU (Coordinator)
    • Idener
    • Lulea Tekniska Universitet
    • Rubico
    • Gorenje Orodjarna, d.o.o.
    • Advantic Sistemas y Servicios
    • IMC Messsysteme GmbH
    • Litostroj Ravne Ltd.


To get a description of the project partners, please click on the respective partner in the navigation bar.

Project

Introduction

iMain is a European level research project aiming to develop a novel decision support system for predictive maintenance. To that end, a multi-layer solution integrating embedded information devices and artificial intelligence techniques for knowledge extraction and novel reliability & maintainability practices will be developed. The resulting solution will provide extended capabilities compared to those achievable with current state-of-the-art maintenance practices, increasing system lifetime of the production equipment at least 30%, energy efficiency at least 20%, availability of whole process at least 30% while decreasing maintenance costs at least 40%.

Motivation

The iMain project is strongly committed to deployment issues, including innovation and implementation actions focused on value chains and bridging the gap from research to market. iMain acknowledges the significance of exploitation, puts emphasis on the commercialisation of results, also taking into account the needs of post-project monitoring of the commercialisation process. Monitoring progress after the project end will reveal the results of the funding received and evaluate the effectiveness of the innovation mechanism developed.

Objectives

As a step towards the Horizon2020 strategy, the iMain project will thus make a contribution in terms of R&D investment, employment and resource efficiency, aiming to assist EU manufacturers, particularly SMEs, to adapt to global competitive pressures by increasing the technological base of EU manufacturing through the development and integration of the enabling technologies of the future, specifically engineering technologies for novel predictive maintenance solutions.


Gesamtkonzept

Fig.:Predictive maintenance concept

FRAUNHOFER IWU (Coordinator)

Who we are

FRAUNHOFER IWU is one of the largest and most renowned research institutes for industrially-led production technology in Germany. The core competencies of the institute are formed by the development of intelligent production devices for forming and cutting technologies and high-performance manufacturing processes.
A main focus lies on the development of intelligent production systems for the manufacturing of car bodies and powertrain components, as well as the optimization of their related forming and cutting processes.
FRAUNHOFER IWU creates innovative solutions for continuous process chains, from the components, to assembly units, all the way up to complex machine systems and completely new kinematics.

Contact

Dr.-Ing. Steffen Ihlenfeldt
Fraunhofer Institute for Machine Tools and Forming Technology IWU
Reichenhainer Straße 88
09126 Chemnitz
Germany

Tel: +49 371 5397 1494
Fax: +49 371 5397 61494

http://www.iwu.fraunhofer.de

IDENER

Who we are

IDENER is a high-tech research intensive SME originally rooted in a leading Systems and Control Engineering R&D group at the University of Seville’s School of Engineering. One of its distinguishing traits is the sound scientific background of its research team, which is now specialized in a number of disciplines: chemical engineering, electrical and computer science, systems and control engineering, industrial engineering and telecommunications engineering.
Moreover, IDENER aims to incorporate advanced design and optimization tools and skills from the early development phases of new systems to process scale-up and prototype demonstration. To that end, concepts from four interrelated and complementary areas of knowledge: Mathematical Modelling and Simulation; Multidisciplinary Design Optimization; Control Engineering and Software Engineering are integrated.
This approach results in a high added value which sharpens the competitive edge of complex systems. These disciplines are seamlessly integrated into other knowledge areas so as to develop new systems and processes with the aim of contributing to sustainable development in key research areas: Industrial Technologies; ICTs; Biotechnology; Secure, Clean and Efficient Energy; and Resource and Raw materials Efficiency.

Contact

Optimizacion Orientada a la Sostenibilidad SL
18 PISO 2, Avenida Leonardo Da Vinci
41092 Sevilla
Spain

http://www.idener.org/

LULEA TEKNISKA UNIVERSITET

Who we are

LULEA UNIVERSITY OF TECHNOLOGY (LTU) has more than 150 professors and over 600 doctorates, carrying out research in close cooperation with worldwide companies such as Shell, Ericsson, Ford, Volvo, LKAB, Saab Aerotech, Saab Aerosystems, Airbus, SKF, ABB and Volvo Aero and with the University’s international partners such as Monash University and Stanford University. This research has a turnover of EUR 80 million.
LTU has a total of 124 on-going EU projects, including 42 FP6 and FP7 projects. The Division of Operation and Maintenance Engineering focuses on E-Maintenance from a system-oriented perspective. The group, established in 2002, is now a currently leading research group in Europe and is also globally recognised by leading researchers in the field. It consists of more than 52 active researchers and contains a critical mass of R&D personnel from backgrounds that add necessary depth. The division has been working in close collaboration with Swedish and European industries, and has been successful in securing European and nationally funded projects like FP7, Swedish Foundation for Strategic Research and the Swedish Governmental Agency for Innovation Systems. In addition to that they have secured long-term strategic research grants from the Swedish Transport Administration.

Contact

Dr. Phillip Tretten
Lulea University of Technology
University Campus, Porsoen
SE97187 Lulea
Sweden

Tel: +46 70 566 49 40
Fax: +46 920 49 13 99

http://www.ltu.se/

RUBICO

Who we are

RUBICO AB – THE DSP CONSULTANTS was founded in January 2004 as a Swedish SME and focuses on embedded systems and the area of digital signal processing. The company created a niche with a bearing both nationally and internationally through partnerships and close collaboration with technology providers.
For example, RUBICO is a member of Analog Devices (ADI) “The Collaborative” and Telit “Competence Center” which is the third-party guarantee of excellence and quality. RUBICO also does development projects directly towards the ADIs headquarters in Boston, which is an excellent reference for all customers seeking DSP skills. RUBICO has profiled itself as a technology consultant, but has also done its own product efforts. One of these resulted in the talking newspaper receiver Adela, which today is used daily by over 9000 visually impaired and blind people to meet their news needs.
Starting in 2009, RUBICO has developed a novel technique for condition monitoring of rolling bearings based on vibration analysis. The technology is patented in Sweden and an international extension of the patent has been initiated by a PCT application. The uniqueness of this method is the signal processing algorithm used to extract the so-called shock vibrations occurring in connection to bearing failures. Based on very promising results from preliminary tests, current activity includes long-term testing in harsh industrial environment as well as continued research and development.

Contact

Rubico Consulting AB
Aurorum 6
97775 Lulea
Sweden

http://www.rubico.se/

GORENJE ORODJARNA, D.O.O.

Who we are

GORENJE ORODJARNA, D.O.O. (GORENJE) is the biggest tool and mould making company in Slovenia and one of the biggest tool and mould making companies in the Central and Eastern European Countries. The company specializes in development, manufacturing, marketing and maintenance of a variety of tools for sheet metal processing, injection moulding, thermal processing and Styrofoam packaging as well as measuring systems for the control and testing of appliance functions and safety features.
GORENJE has a highly motivated R&D team, with more than 35 people employed in the operative R&D Department, who are registered also with the Slovenian Research Agency.
GORENJE uses numerous processes including milling, grinding, drilling, turning, WEDM and EDM, measurements and laser processing. For each and every process, Gorenje Orodjarna has highly skilled staff and matching technological equipment, which is further complemented by tool testing machines such as hydraulic and mechanical presses, and a five-axis laser centre.

Contact

Gorenje Orodjarna, d.o.o.
Partizanska cesta 12
3320 Velenje
Slovenia

http://www.gorenje-orodjarna.si/

ADVANTIC SISTEMAS Y SERVICIOS

Who we are

ADVANTIC SISTEMAS Y SERVICIOS (ADVANTIC) is a high-tech Spanish SME which has an important background in information and communication technologies specialized in the field of wireless sensor networks (WSN) and other remote monitoring systems. Nowadays WSN has a huge variety of applications and business markets such as energy and industry processes.
One of the most important challenges for ADVANTIC is the development of its skills in R&D projects in order to extend the market opportunities being totally involved not only in the state of art of the sensor market but also contributing to the development of the area.
Thanks to its solid technological background in WSN, its collaboration network, and its highly skilled multidisciplinary professionals, ADVANTIC is capable of offering its clients competitive and effective technological solutions. ADVANTIC provides a wider variety of products and services: wireless remote monitoring systems applied to different environments, viability studies, professional training and R&D Consultancy. Additionally, ADVANTIC participates in R&D projects at National and European level and in different Spanish Technology Platforms.

Contact

Advantic Sistemas Y Servicios
Avenida de Europa 14
28108 Alcobendas (Madrid)
Spain

http://www.advanticsys.com/

IMC MESSSYSTEME GMBH

Who we are

IMC MESSSYSTEME GBMH (IMC) was incorporated in 1988 as a German SME in response to its founders’ vision of the dramatic changes PCs and graphical user interfaces would soon bring to instrumentation. As a pioneer in Windows-applications and a producer of PC-based measurement technology, IMC very soon became one of the leading companies in this field. Their products are at the innovative forefront of the market. Their philosophy emphasizes cultivating intensive customer relationships and high-quality service. IMC is one of the leading suppliers of PC-based physical data acquisition systems in the field of instrumentation. As producers of hardware and software for instrumentation, they currently employ 130 engineers at their product development facilities in Berlin.

Contact

IMC Messsysteme GmbH
Voltastrasse 5
13355 Berlin
Germany

http://www.imc-berlin.com/

LITOSTROJ RAVNE LTD.

Who we are

LITOSTROJ RAVNE LTD. (LR) is a manufacturer of high quality custom-made industrial hydraulic and mechanical presses for sheet metal forming with nominal force from 400 to 40.000 kN, with length of a table up to 8 meters. Furthermore, LR develops and produces press line equipment and is able to deliver complete press systems. Their hydraulic and mechanical presses and press line machinery are integrated in production facilities of many suppliers and producers in automotive and household appliances industry.
LRs motivated engineers and service technicians provide optimization solutions for any need. Working in close cooperation with a customer, they develop and implement demanding solutions to manufacture or enhance custom-made press lines or their performance in steel and metal forming industry. The whole process from requirement analysis through design and technical construction to manufacturing is in-house controlled.
LR has developed all crucial production capacities and mastered in most advanced know-how needed in high performance stamping press manufacturing. They understand the demanding 24/7-production environment that the majority of the metal forming companies operate in and have put much effort into providing the critical service and maintenance support.

Contact

Listostroj Ravne Ltd.
Koroska Cesta 15
2390 Ravne Na Koroskem
Slovenia

http://www.litostrojravne.com/

Work Packages

    • WP1 – Advanced Condition & Energy Models
    • WP2 – Embedded Condition & Energy Monitoring system
    • WP3 – Smart Service Life & Energy Prediction System
    • WP4 – E-maintenance cloud
    • WP5 – Integration and Industrial Scale Demonstration


To get a description of the activities of the technical work packages, please click on the respective work package in the navigation bar.

Work packages 6 and 7 concentrate on the dissemination and the administrative and financial management of the project during the whole duration.

WP1 – Advanced Condition and Energy Models

Time period

September 2012 – December 2013

Activities planned in WP1

Smart predictive maintenance of production equipment needs a new concept of optimal combination and processing of different information sources like control-inherent sensors, additional real sensors and model-based virtual sensors. The equipment information extraction will be realized by Embedded Condition & Energy Monitoring (ECEM). ECEM needs system identification to provide optimal knowledge about maintenance-relevant components, the availability of inherent information and the optimal placement of additional sensors.
Work package 1 aims to create a model-based ECEM including an optimal combination of different information sources as the base for predictive maintenance.
In some special cases like mechanical behaviour of frame components, model-based system identification (e.g. FEM simulation) could provide information about conditions like mechanical stress distribution much more effective than experiments and will be used for detection of critical zones and an optimal sensor placement.
By means of simulation models the components’ influence on energy consumption of equipment will be detected. Additionally, the service life will be determined by evaluating the monitored conditions and information about maintenance-relevant components. For prediction, the future behaviour of components in real production, considering varying parts and loads, has to be evaluated. Therefor failure mechanisms and mathematical evaluation methods (e.g. fatigue life hypotheses) have to be specified.

Partners involved in WP1

  • Fraunhofer IWU (leader of this WP)
  • IMC
  • Advantic
  • Rubico
  • Idener
  • LTU
  • LR
  • Gorenje

WP2 – Embedded Condition and Energy Monitoring System

Time period

January 2013 – October 2014

Activities planned in WP2

Just-in-Time-Productions become more and more an integral part of batch fabrication. An unexpected downtime or even a wear-related energy waste of the machine is hardly to compensate. Reactive maintenance models lead in almost every case to non-predictable production interrupts and in many cases to an increase in energy consumption per unit. Preventive models on the other with fixed maintenance periods lead to an increase in costs, because the wear tolerance was not utilized fully. In the future a condition-based maintenance of machines and plants will be mandatory for economic success. In contrast to conventional “tachographs” modern condition monitoring systems must be able to interpret the data influx and evaluate these in a compact and practice-oriented manner.
Work package 2 aims to develop the Embedded Condition and Energy Monitoring (ECEM) system (hardware and software). Therefore, a selection of process parameters for an economic and reliable evaluation of mechanical strains and stresses, wear tolerances and and energy consumption is necessary.
The condition monitoring systems will be integrated into the production process and supplemented with energy monitoring functions.
The implementation of the ECEM-system, which should operate nearly personal self-sufficient, will be carried out by the example of press lines.

Partners involved in WP2

  • IMC (leader of this WP)
  • Advantic
  • Rubico
  • LTU
  • Fraunhofer IWU
  • LR
  • Gorenje

WP3 – Smart Service Life Prediction System

Time period

September 2012 – February 2015

Activities planned in WP3

Smart predictive maintenance of production equipment needs information about the expected remaining service life of critical components of the production equipment. Thereby it will deliver considerably more information than conventional condition monitoring systems and for the first time maintenance becomes plannable with an optimal usage of remaining service life. For it, the deterioration process of components has to be predicted, based on real loads/disturbances, deterioration history and future load scenarios.
Work package 3 aims to develop a Smart Service Life Prediction System (SSLP), which is able to predict the deterioration process of components, based on simulation models. For consideration of real loads, it is necessary to develop an IT infrastructure and interface for embedded just-in-time simulation in forming presses, where external information sources (e.g. control, additional sensors) can be integrated. In addition, the simulation accuracy should be observed and evaluated by another software module. In the result of WP3, evaluated “just-in-time” information about estimated remaining service life will be delivered on defined interfaces. Furthermore, improvements in future design of equipment components can be derived from this information and will be summarised in this WP.

Partners involved in WP3

  • Idener (leader of this WP)
  • IMC
  • LTU
  • Fraunhofer IWU
  • Gorenje

WP4 – E-Maintenance Cloud Development

Time period

September 2012 – August 2015

Activities planned in WP4

In maintenance, Reliability Centered Maintenance (RCM), Condition Based Maintenance (CBM) and Total Productive Maintenance (TPM) are all well-known strategies that have been recognised for a number of years. The contents of those strategies are defined widely in standards and literature. However, in spite of the history and soundness of technology the adaptation of those maintenance strategies has not fully matured.
Work package 4 aims to provide a system definition for an E-Maintenance Cloud based on industrial priorities and available technologies. The system architecture will comprise user interfaces, data storage and history as well as predictive maintenance organization and management. Emphasis will also be placed on the predictive maintenance ecosystem, highlighting the interdependencies along with other enterprise resource planning services and conducting activities aimed at integrating predictive maintenance in the overall production strategy. Moreover, models and technology for an estimation of Remaining Useful Life (RUL) will be analyzed.

Partners involved in WP4

  • LTU (leader of this WP)
  • Advantic
  • IMC
  • Rubico
  • Fraunhofer IWU
  • LR
  • Gorenje

WP5 – Integration and Industrial Scale Demonstration

Time period

March 2014 – August 2015

Activities planned in WP5

Work package 5 aims testing the developed technologies and methodologies in the industrial scale and in conjunction with the necessary industrial press equipment. Accordingly, the tests will be performed both in a small mechanical eccentric press and in a large hydraulic press. Thereby functionality, advantages and industrial need of the new products should be proven and a European Business network should be established.

Partners involved in WP5

  • Gorenje (leader of this WP)
  • Advantic
  • IMC
  • Rubico
  • Idener
  • LTU
  • Fraunhofer IWU
  • LR

Announcements

iMAIN will present on AMA Congress 2015, SENSOR 2015 - IRS2 2015, 19. - 21. Mai 2015, Nürnberg

Title: iMAIN project: Advanced Condition Monitoring Concepts Allow Predictive Maintenance - Incorporating Virtual Sensor Simulation and Cloud Based Decision Making

Downloads

Press releases

FRAUNHOFER: Health screening for industrial machines (also printed)

PHYS.ORG: Health screening for industrial machines

SPRINGER: Vorausschauende Instandhaltung in der Industrie 4.0

IT-MARKT: Die nächste industrielle Revolution

IT-MODERNE INFORMATIONSTECHNIK 12/2014: Vorsorgeuntersuchungen für Industriemaschinen (printed)

SILICON SAXONY: Chemnitzer Forscher bringen Industrie 4.0 in Umformmaschinen

FRAUNHOFER: Vorsorgeuntersuchungen für Industriemaschinen (also printed)

ELEKTRONIK PRAXIS: Industrie 4.0: Virtuelle Sensorik macht reale Sensoren nahezu obsolet

MM MASCHINEN MARKT: Industrie 4.0: Virtuelle Sensorik macht reale Sensoren weitgehend überflüssig

SCIENCE DAILY: SCIENCE DAILY: Health screening for industrial machines

AT-AANDRIJFTECHNIEK: AT-AANDRIJFTECHNIEK: Bewaking machines met virtuele sensoren

Publications

Wabner, M., 2015, IT based networking of machines – a novel approach for predictive maintenance in forming, 29. Internationales Forum für industrielle Instandhaltung - ÖVIA Kongress vom 7. - 8. Oktober 2015, Bad Erlach, Austria.

Wabner, M., 2015, Predictive Maintenance in Forming Machines, presentation at RIETER Lead User Workshop, RETER Management AG, Winterthur, Switzerland

Riedel, M., 2015, iMAIN project: Advanced Condition Monitoring Concepts Allow Predictive Maintenance - Incorporating Virtual Sensor Simulation and Cloud Based Decision Making, AMA Congress 2015, SENSOR 2015 - IRS2 2015, 19. - 21. Mai 2015, Nürnberg

Wabner, M.; Riedel, M.; Ihlenfeldt, S., 2015, Industrie 4.0: Vernetzung von Industriemaschinen ermöglicht neue Qualität bei der vorausschauenden Instandhaltung, IM+io – Das Magazin für Innovation, Organisation und Management, imc Verlag, Saarbrücken, 1:53-58

Wabner, M.; Riedel, M.; Ihlenfeldt, S., Friedemann, M., 2015, Produktionsanlagen im Wandel – intelligente Instandhaltung mit Industrie 4.0, Computer&AUTOMATION, WEKA FACHMEDIEN Verlag, Haar, 1:11-16

Naumann, C., Langer, T., Wabner, M., 2015, Ressource Daten - Datennutzung im produktionstechnischen Umfeld, Vortrag, IuK Branchenforum: Big Data - Wer weiß mehr?, 19.02.2015, Hannover

Steffen Ihlenfeldt, Martin Riedel, Markus Wabner, Robert Tehel, Marcel Tistl, Jochen Fischer, 2014, Novel Maintenance Support System for Frame Components of Forming Presses, European Congress & Expo on Maintenance and Asset Management, 22, 2014, Helsinki, World Congress & Global Forum on Maintenance and Asset Management, 6, 2014, Helsinki, pp 471-476.

Diego Salazar, Gerardo Glorioso, Markus Wabner, Martin Riedel, 2014, Maintenance support wireless system for ram of forming presses, Proceedings of Maintenance Performance Measurement and Management (MPMM) Conference, 9, 2014, COIMBRA, In: SALAZAR, Diego; et al. - Maintenance support wireless system for ram of forming presses. Coimbra: Proceedings of MPMM Conference, pp 89-93.

Steffen Ihlenfeldt, Markus Wabner, 2014, iMAIN - A Novel Decision Support System for Intelligent Maintenance, Conf. presentation, CIRP Januray Meeting, Paris.

Blau, Peter; Fischer, Jochen; Praedikow, Michael; Päßler, Thomas, 2014, Einsatzpotenzial von Condition Monitoring Systemen an Servopressen (Potential of Condition Monitoring Systems in Servo Presses), EFB-Kolloquium Blechverarbeitung, 34, 2014, Fellbach, pp 217-229.

Fischer, Jochen, 2013, Überwachungssysteme in der Produktionstechnik - Interaktion zwischen Prozess-, Maschinen- und Energieüberwachung (Monitoring Systems in Production Technology - Interaction Between Process-, Machine- and Energy Monitoring), Workshop Systematisch Energieeffizienz einbinden und festigen, 2013, Zwickau, Conf. Speech.

Products & Services

Integrated iMAIN maintenance support system

It provides an extended modular CM system with improved decision support, including inferred sensors for frame components. It helps predict critical parts and the remaining lifetime of press components and can visualize the data in the iMain cloud for specific users and uses. The demonstrator at industrial partner Gorenje will be the Reference System for documentation, demonstration and showcase purposes.

More info as PDF


Remote data monitoring

A wireless technology to access data remotely. To provide a monitoring that wasn’t previously accessible in remote locations or locations that need wireless solutions. A comprehensive but easy to use software with efficient data analysis is also provided.

More info as PDF


Online RUL prediction of press frame monitoring

IT system attached to a forming press machine capable of calculating RUL of frame components using failure accumulation theory.

More info as PDF


Energy consumption optimization tool

Development of an adaptable and stand-alone energy model (Customizable eMODEL) of forming presses to estimate influences on the energy consumption for technology/process improvement, parameter optimization and system improvement (design of energy recovery systems).

More info as PDF


Virtual Sensors ANN

The result to be exploited is an Artificial Neural Network (ANN) object aimed to the estimation of strains in press frame components at non-accessible geometries as well as the general minimization of physical strain sensory in strain monitoring. To that end, the ANN object infers "virtual sensors" state from data from real sensors. This ANN object can be easily implemented in commercial programme languages, such as C++.

More info as PDF


New generation of IT based press equipment

Development of a new generation of IT based press equipment and service with increased life time and energy consumption.

More info as PDF


Wireless temperature monitoring system

Development of a temperature monitoring system capable of collecting information from sensors placed in any kind of press and providing a certain level of autonomy and lifetime duration through energy harvesting and wireless synchronization techniques. It will be used to prevent the occurrence of breakdowns by detecting problems from the very start and making repairs and replacements before actual breakdowns occur or cause other more expensive problems. IMAIN will make machines more reliable and predictable by monitoring their performance. The results may be widespread and applied to any other measurement parameter in order to obtain a global monitoring system to help management of facilities by creating optimal, safe and cost-effective systems that comply with corporate and regulatory standards.

More info as PDF


MEMS-based vibration sensors

Improved MEMS-based vibration sensors.

More info as PDF


CM expertise for forming presses

Extensive experience in practical implementation of condition monitoring in press machines.

More info as PDF


3rd. party device interface 3PDI

Framework for 3rd. Party devices integration including concept for individual licensing of the resulting components and applications.

More info as PDF


Life Data Processing Framework

Framework for live data processing - based on PC platform.

More info as PDF


Links

  • other related FP7-projects

    • Power-OM (Power consumption driven Reliability, Operation and Maintenance optimisation)
    • Supreme (Sustainable Predictive Maintenance for Manufacturing Equipment)
  • iMain is a member of the following clusters:

    • FOCUS (FOCUS will support methods for improved exploitation of FoF project results from our five participating FoF clusters.)
    • FOCUS-LOGO

    • Co-FACTOR (Co-FACTOR aims at speeding-up the industrial up-take of results of FoF projects about "smart components".)
    •          Co-FACTOR-LOGO

Imprint

The Fraunhofer Institute for Machine Tools and Forming Technology IWU
Reichenhainer Straße 88
09126 Chemnitz, Germany
Internet: www.iwu.fraunhofer.de
E-Mail: info(at)iwu.fraunhofer.de
Phone: +49 371 5397 0

is a constituent entity of the Fraunhofer-Gesellschaft, and as such has no separate legal status.

Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
Hansastraße 27 c
80686 München
Internet: www.fraunhofer.de
E-Mail: info(at)zv.fraunhofer.de

VAT Identification Number in accordance with §27 a VAT Tax Act: DE 129515865

Court of jurisdiction

Amtsgericht München (district court)
Registered nonprofit association
Registration no. VR 4461

Executive Board

Prof. Dr. Reimund Neugebauer, President of the Fraunhofer-Gesellschaft, Corporate Management and Research
Prof. Dr. Ulrich Buller, Research Planning
Dr. Alfred Gossner, Finance and Controlling (incl. Business Administration, Purchasing and Real Estate), IT
Dr. Alexander Kurz, Personnel Affairs and Legal Affairs

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General Contact

Dr.-Ing. Steffen Ihlenfeldt
Fraunhofer Institute for Machine Tools and Forming Technology IWU
Reichenhainer Straße 88
09126 Chemnitz

Tel: +49 371 5397 1494
Fax: +49 371 5397 61494

E-mail: steffen.ihlenfeldt(at)iwu.fraunhofer(dot)eu

International Event: Demonstration Seminar of FP7 Project iMAIN

Written by Markus Wabner, Fraunhofer IWU

Tuesday, 02 Jun 2015

Demonstration Seminar of FP7 Project iMAIN – A NOVEL SUPPORT SYSTEM FOR PREDICTIVE MAINTENANCE IN FORMING

Enjoy the latest cloud based innovations in Condition Monitoring and take part in discussions and live demonstrations with end users, machine builders and research experts. Accommodation will be available the night before the seminar at HOTEL PAKA in Velenje. Please register via e-mail until June, 15th (contact@imain-project.eu). Due to the fact that the seminar space is limited, first registrations will be handled with higher priority. We are looking forward to receiving your registration until June 15th, 2015 and welcoming you at HOTEL PAKA in Velenje.

Flyer with detailed info including the schedule as PDF

gorenje-LOGO

Virtual Sensor Technology successfully implemented

Written by Robert Tehel and Markus Wabner, Fraunhofer IWU

Wednesday, 03 Dec 2014

Using virtual sensors for minimizing the number of real sensors in strain measurement

The frame components of forming presses are highly stressed parts. Since the application of real sensors in every critical zone is not affordable and not efficiently enough, all the necessary data for the estimation of remaining useful lifetime are acquired now with a minimal amount of real sensors.

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Figure: Strain measurement in forming machines with virtual sensors

This demand can be accomplished by connecting the few real sensors (mainly strain gauges) via advanced finite element simulations to the critical zones. Therefore several transfer algorithms has been designed with difficult requirements:

  • cover all occurring load cases
  • usage of as less as possible real sensors
  • as exact as possible prediction of stress states
  • ability for online data processing

These algorithms contain situation based approaches via artificial neural networks, polynomial combination or weighted pseudo-load cases. With these transfer algorithms it is possible to estimate the stress state in the whole frame components out of a small number of real sensors (for example at the side columns) which allows the prediction of the remaining useful life time for these components.

The virtual sensors can also include a variety of other real sensors next to the strain gauges affecting the health of the frame components or even other components in the forming machine. This means, that different sensor types in different parts of the forming machine can affect the state of health of a component and that the remaining useful life can be estimated through a virtual sensor without having a real sensor on this component.

To ensure the accuracy of the virtual sensors even for a long period, an additional observation module has been installed, which can also be considered as a self-monitoring function of the condition monitoring system. This module compares permanently a few virtual sensors with real sensor data and will detect deviations.

Virtual sensor technology can be considered as a very beneficial approach, if high-value systems like forming presses, but also a higher amount of low-value systems have to be monitored. A main advantage is, that the number of real sensors can be minimized, which minimizes the technical and financial effort and increases the reliability of condition monitoring systems. In addition, virtual sensory has to be developed only once, but can be applied in all other similar systems.

iMAIN at EUROBLECH 2014

Written by Petra Petra Janežič, Gorenje Orodjarna, d.o.o.

Monday, 18 Aug 2014

iMAIN and Gorenje Orodjarna at EUROBLECH 2014

October 21 – 25, 2014, HANNOVER, GERMANY

Gorenje Orodjarna, d.o.o.

iMAIN is installing two condition monitoring systems in automotive industry

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN is installing two condition monitoring systems in automotive press machines

iMAIN is currently installing two condition monitoring systems for predictive maintenance in sheet metal forming machines in automotive industry. The first system is applied to a 3.200 tons press at a automotive supplier in Germany. Press load, force vector eccentricity, ram tilting, mechanical strains and stresses, oil and lubricant quality and air consumption are monitored.

The other system is installed in a 2.000 tons sheet metal forming press of a large German car manufacturer. Press load, force vector eccentricity, ram tilting, oil and lubricant quality as well as air consumption are monitored.

iMAIN installed condition monitoring system in Switzerland

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN installed a condition monitoring system at a press machine builder in Switzerland

iMAIN has installed a first condition monitoring system in a precision blanking machine of a press machine manufacturer in Switzerland. Besides force monitoring, also vibrations at all main bearings and at the main motor, as well as air consumption, oil quality and energy consumption is monitored.

Cyber Physical Production Systems: Maintenance within Industrie 4.0

Written by Markus Wabner, Fraunhofer IWU

Thursday, 27 Nov 2014

iMAIN Solution for Intelligent Maintenance in Production

Germany's Industrie 4.0 initiative – a part of the Hightech Strategy of Germany's Government – aims to develop networked industrial machinery with built-in intelligence based on smart self-monitoring functions. This will also enable a new quality in maintenance based on a proper and safe IT infrastructure, which has to provide the necessary flexibility regarding permanently changing requirements in terms of information channels, data mining algorithms and added-value services.

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Figure: iMAIN maintenance support system approach within Industrie 4.0

On the demonstration example of forming presses, iMAIN develops an intelligent maintenance support system that will be in line with the Industry 4.0 vision. In the basic understanding of an intelligent and spatial distributed maintenance control loop, the different approaches for embedded data acquisition and pre-evaluation deliver basic information about systems and it´s relevant states. This basic requirement in maintenance which is practically realized in so-called condition monitoring systems, guarantees iMAIN a proper starting position. To satisfy the extended requirements of a sustainability approach within Industry 4.0, conventional data acquisition systems have been significantly enhanced within the project: Besides conventional sensory and control-inherent information, novel solutions for MEMS, wireless sensors and virtual metrology have been developed. In combination with an advanced layout (system structure and architecture) of an Embedded Condition and Energy Monitoring System (ECEM) for data acquisition, data logging, processing and communication, a novel quality of information can be delivered for further processing. The ECEM system comprises a number of novel solutions regarding:

  • A clearly decoupled system architecture defining and separating layers of functionality and hierarchy.
  • Interfacing frameworks that allow integration of heterogeneous hardware components.
  • Data processing platforms that allow embedded signal processing, analysis and data reduction.
  • This data processing system has the ability to flexibly and dynamically alter parameters of the analysis algorithms during continuous operation (“tuneable parameters”).
  • Extended networking and interfacing to cloud based services in conjunction with data acquisition and monitoring.

The "core" of iMAIN maintenance support system will be an intelligent data mining and storage service platform. For this, a modular cloud-based approach has been chosen, which allows location-independent I/O access for stationary as well as non-stationary systems. Depending on customer’s requirements, iMAIN is working on company-internal as well as global solutions. Even if the developments just have started with the needed services for forming presses, the service platform approach allows the implementation of multiple services and algorithms which will enable the system to work with data from different industries as well as data mining and evaluation solutions from third parties. This cloud-based approach addresses a major problem in predictive maintenance, the acquisition of the needed high amount of data and information, which are the base for high-quality RUL estimation. Especially in forming, where failures and breakages do not occur regularly, only data from many similar, but typically spatially distributed systems can help to improve this situation.

To succeed in predictive maintenance, finally the generated knowledge has to be provided for decisions regarding the needed and planned activities. This can be monitoring operators, production planners or service providers which are responsible for maintenance or even the system or press manufactures, which get valuable knowledge for press machine improvement.

iMAIN will present on AMA Congress 2015

Written by Martin Riedel, imc Meßsysteme GmbH

Thursday, 27 Nov 2014

iMAIN project: Advanced Condition Monitoring Concepts Allow Predictive Maintenance - Incorporating Virtual Sensor Simulation and Cloud Based Decision Making

AMA Congress 2015, SENSOR 2015 - IRS2 2015, 19. - 21. Mai 2015, Nürnberg

Abstract

While industrial production environments incorporate more complex and expensive equipment, they decreasingly tolerate failures and downtimes. Forming machines such as mechanical presses are a typical example, where this dilemma becomes particularly expensive and it pays off to be tackled by a predictive maintenance scheme: Based on extensive multi-domain condition monitoring, it aims for assessment of the current “state of health” as well as data that allows remaining useful life prediction. Thus, “just-in-time” maintenance avoids both unnecessary preemptive action as well as reactive measures once the machine has already failed. As one major novelty, iMAIN incorporates additional “virtual sensors”. Strain and load situations at crucial but inaccessible and even buried locations of the press frame cannot be monitored by instrumentation with real strain gauges. However, they are derived from surrounding real sensors with live real-time simulation techniques. Such data, enhanced by a broad variety of additional sensors, bearing analysis, electrical power consumption, machine control information etc. are subjected to extensive preprocessing, analysis and data reduction, before being uploaded to a cloud hosted data base. This platform provides multi-user access and further post processing capabilities. It can unite the expertise and exploit synergies of many involved partners, from machine end user, to press manufacturers and scientific experts in this field.

AMA 2015

iMAIN at EuroMold 2014

Written by Markus Wabner, Fraunhofer IWU

Thursday, 13 Nov 2014

Advanced Condition Monitoring of Forming Presses

November 25 – 28, 2014, FRANKFURT / MAIN, GERMANY

Hall/booth: 11.0/C66

Fraunhofer-Institut für Werkzeugzeugmaschinen und Umformtechnik IWU

EuroMold 2014

iMAIN Demonstration meeting at GORENJE

Written by Markus Wabner, Fraunhofer IWU

Thursday, 13 Nov 2014

iMAIN Solution for Intelligent Maintenance in Production

November 4 - 7, 2014, VELENJE, SLOVENIA

iMAIN project has hold a meeting at the end user GORENJE AG in Velenje, Slovenia to demonstrate the project progress to all partners and to EC. During the successful meeting the main focus was on the demonstration of the test installation of the Embedded Data Acquisition System (ECEM) at a LITOSTROJ RAVNE forming press. The ECEM system is part of a comprehensive condition monitoring system to improve maintenance in sheet metal forming presses. Furthermore it has been demonstrated, how pre-evaluated data are stored in the so-called “E-Maintenance cloud”. Here the load history data will be evaluated by special cloud services regarding alarm-relevant information (remaining useful life, threshold values). The ECEM system as well as a number of sensors can be accessed by remote desktop, mobile phone or tablet PC.

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Figure: Screenshot of the remote desktop user interface of the embedded data acquisition system, which is part of the iMAIN Maintenance support system for forming presses

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Figure: Press machines at Gorenje AG

iMAIN presentation at MPMM 2014

Written by Gerardo Glorioso, Advantics and Markus Wabner, Fraunhofer IWU

Monday, 18 Aug 2014

Maintenance Support Wireless System for Ram of Forming Presses

September 4 - 5, 2014, COIMBRA, PORTUGAL: The iMAIN partner ADVANTIC – a high-tech Spanish SME which has an important background in information and communication technologies specialized in the field of wireless sensor networks (WSN) – has presented “Maintenance Support Wireless System for Ram of Forming Presses” in the E-MAINTENANCE Session at the Maintenance Performance Measurement and Management Conference 2014 (MPMM 2014).

ABSTRACT

Diego Salazar • Gerardo Glorioso • Markus Wabner • Martin Riedel

In the paper, an innovative wireless system for press ram stress monitoring will be presented as component of a decision support system for predictive maintenance. This system involves low power consumption wireless nodes and energy harvesting techniques to gain autonomy for the whole solution. Its output signals serve for the monitoring system to extract and generate “virtual sensor” signals. These represent actual load and stress situations on locations that are crucial for machine stability but are inaccessible for real measurement or even buried inside the frame structure. In addition, the monitoring system is embedded into a networked environment of an e-maintenance cloud, linking a variety of information sources like enterprise resource planning.

MPMM 2014