Creating Future Powertrain Manufacturing Capability: An ... · Creating Future Powertrain Manufacturing Capability: An Automation Perspective PfProfessor Rb tRobert HiHarrison Head

Creating Future Powertrain Manufacturing Capability: An Automation Perspective

P f R b t H iProfessor Robert HarrisonHead of Automation [email protected]

An academic department ithin the science fac lt of a

WMG ‐ An IntroductionAn academic department within the science faculty of a leading UK university

Established in 1980 to facilitate technology transfer and knowledge creation for Industry

750+ people (university and industry) working in 5 buildings (with funding further new buildings)

Professor Lord Bhattacharyya

Training over 2,500 individuals in the UK and abroad (covering Engineering Business Management to Manufacturing Engineering ‐ school to post experience)

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Founder and Chairman of WMG

Manufacturing Engineering school to post experience)

Co‐located with Tata Steel, Jaguar LandRover, & Tata Motors European Technical CentreMotors European Technical Centre

One of the seven HVM Catapult centres.

© Automation Systems Group, WMG, University of Warwick, 2014

WMG FaciltiesI t ti l M f t i C t• International Manufacturing Centre

– Automation Systems, Digital Lifecycle Management, International Comparisons

– Materials & Manufacturing- Light-weighting , Materials Processing, g g g g , g,– Sustainable Materials , Metrology

• International Digital Laboratory– Digital Healthcare with Warwick Medical School– Cybersecurity, Experiential Engineering, Medical Informatics, Visualisation– Business focused automotive research

• International Automotive Research CentreB tt Ch i t d E I ti C t E & El t i l– Battery Chemistry and Energy Innovation Centre; Energy & Electrical Systems

– Virtual Engineering and Prototyping– Commercialisation

• International Institute for Product and Service Innovation– Multifunctional Systems , Nanotechnology– Business Transformation and Service Science– Small Firms Centre

• Engineering Management Building– Professional and Executive Programmes


NAICNational Automotive Innovation CampusNational Automotive Innovation Campus

£100m investment from Government (£25m) and industry.

33 000 2 f ll b ti R&D33,000 m2 of collaborative R&D space.

© Automation Systems Group, WMG, University of Warwick, 2014Artist’s Impression

NAICNational Automotive Innovation Campus

Lead research addressing the long‐term industry‐led strategy of the UK Automotive Council.led strategy of the UK Automotive Council.

Drive the UK Automotive resurgence, sustaining jobs, anchoring suppliers, attracting new suppliers,

bl h d d lenabling major growth and increased employment in the sector and beyond.

Collaborate with centres in the US, Europe, Japan,Collaborate with centres in the US, Europe, Japan, India and China and facilitate high value add inward investment with global Tier 1 suppliers moving to the UK and repatriation of supply h ichains.

A symbiotic relationship between academia and industry will link science, engineering andindustry will link science, engineering and enterprise; co‐locating staff from WMG and Warwick, other Universities, SMEs and suppliers.

© Automation Systems Group, WMG, University of Warwick, 2014Artist’s Impression

WMG Academy for Young Engineers

Education and TrainingWMG Academy for Young EngineersUniversity Technical College based on the edge of the campus (14+) opening 2014Undergraduate Engineering DegreeWMG staff members deliver ~25% of the Engineering MEng/BEng Degree Courses inWMG staff members deliver 25% of the Engineering MEng/BEng Degree Courses in partnership with the School of Engineering Undergraduate Applied Engineering DegreeStarting September 2013 – 4 year Part‐time undergraduate degree leading to a BEng inStarting September 2013 4 year Part time undergraduate degree leading to a BEng in Applied Engineering with specialisation during years 3 & 4.Full Time Masters & Part Time Professional Programmes12 full time courses (technical and non technical) + Foundation, Award and certificate courses Technical Accredited Scheme Masters level modules in low carbon, electronics and software technologies network of HE centres of excellence in key technologies managed by WMG.International Doctorate CentreEPSRC‐backed Doctorate combines academic and industrial expertise, offering industry‐l t h d t htrelevant research, and taught courses.

PhD ProgrammeTraditional 3‐4 year PhD programme.


Automotive Research

Digital Lif

Sustainab

Design

Forming

Joining

Performa

Simulatio

Electroch

Energy an

Autom

at

Materials

Business

fecycle Ma

bility

ance

on hemical En

nd Electric

ion

s Processi anageme

ngineering

cal System

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Materials: Steels

Materials: Light Alloys

Materials: Composites

Systems: BIW, Chassis, Powertrain

Systems: Hybrid, EV, Electrical


Creating Future Powertrain ManufacturingCreating Future Powertrain Manufacturing Capability: An Automation Perspective

• Education and trainingT hi d t d t j t– Teaching and student projects

– Physical demonstrators (legacy, current-best, future)

• Research and developmentResearch and development– Future methods, tools and technologies

U d i li ti i i– User-driven applications engineering


Automation Systems Group

• Currently ten researchers expanding

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• Currently ten researchers, expanding• Moved to WMG from Loughborough in Spring 2013

E l t ti t ti it• Example areas automation systems activity• Engineering lifecycle support• Supply chain integration• Supply chain integration• Knowledge capture and reuse• Energy consumption modelling• Process/Machine optimisation• Control system deployment

• User-Driven Collaboration


Industrie 4.0


Automation Systems Scopey pVirtual Commissioning

Automation Systems

Web Services and SoA

Maintenance

Energy

Weather

Production Demand/Supply

Automation Systems Workbench

Runtime Control

Lifecycle Engineering

Building Automation System

Production System

Augmented Reality

Unity Pro/ STEP 7

PLC or embedded devices

Production System

Automation Systems Demonstrator


Automation Systems ‐ FocusAutomation Systems ‐ Focus

Modelling Deployment SupportModelling eployment Support


Areas of Training UG PG and R&D ActivitiesAreas of Training, UG, PG and R&D Activities

• Industrial applications engineeringIndustrial applications engineering• Virtual engineering and commissioning• Control systems (PLC, Drives, HMIs)• Web Services, SoA, Cloud Computing, , p g• Migration from legacy to current and future

technologiestechnologies• Collaborative engineering

( l h i )(across supply chain)


Case Study – Powertrain assembly

o Oil pan rundown o Block load o Trigger wheel assembly o Engine offload o Manifold rundown o Coolant cavity leak testo Coolant cavity leak test o Ball seal and cup plug o Clutch assembly

o RTV oil pan

o Intake tappet selection o Exhaust tappet selection o Tappet verification

o Tappet selectiono Machining cells

(MAG, Marposs, EWAB, Liebherr)

Misc.(MAG, Marposs, EWAB, Liebherr)


Component based concept and data reuse

CAD control kinematicsata

ng. FBs Software Template

EE

I/Os

+ +

Eng. d

Pre

En

+EN

ENOEN

ENOEN

ENO

+

nts

Re-usable l ibrary

Compone

Mappin

g

C Re-usable l ibrary

M

Step 7

Unity Pro

Syste

m

allation

Re-usable l ibrary Inst


Lifecycle SupportLifecycle Support

System SimulationAuto‐ Semi‐ or Manual Stations • Cycle time verificationAuto , Semi , or Manual Stations • Cycle time verification

• Process verification• Complexityp y• Clash checks• Energy utilisation

/• MODAPTS/MTM generation• Operator fatigue rating• Ergonomic study• Ergonomic study


Assembly Automation


Lifecycle Example

Virtual

Control Logic

MMessages

HMI Information

…

… DeployCapture & Reconfiguref g

Physical (PLC or Distributed Device)

Step 7 for SIEMENSDownload

Unity Pro for SE


Automation Systems Workbench & DemonstratorAutomation Systems Workbench & Demonstrator


Automation Systems DemonstratorAutomation Systems Demonstrator


Cyber Physical Systems


Design data• 3D CAD• Layout

P• Process• Resource

Facilities / Building

AR Applications for Shop Floor Level:‐ Real time production monitoring

Real time data• Control state• Energy• Production mon.

Manual Operation

Real time production monitoring‐ Direct system data access‐ System design support‐ Enhanced Training‐ Maintenance support

Real time collaboration• Sensing(temp, vib)

Vid f d

‐ Real time collaboration‐ Etc.

History data/logs• Maintenance• Production Log• Training

AutomationCapture/Display devices

Video feed QR/Image recognition

Data feed

Digital/Virtual Environment Real EnvironmentAugmented Reality

de ces


T d fl t i f ti i f t tTowards a flat information infrastructure

ISA‐95


SS

Assembly Automation

SS

SS

SS

SS S

SS


Migration to Cyber Physical Systems and SoAMigration to Cyber Physical Systems and SoAEmergent Behaviours

S iS i

Migration Path 1

Migration Path iService Cloud

Service Cloud

Control / InterlockingControl / Interlocking

Sensor/Actuators

Process

Sensor/Actuators

ProcessMigration Path n

Current Implemented SystemsLegacy

Next GenerationSoA-based System

Source: IMC‐AESOP


Building Capability:Thoughts to End onThoughts to End on

Collaboration• Tell us your needs – industry-driven teaching, training and R&DTell us your needs industry driven teaching, training and R&D• Use our facilities with us – student projects, training modules, EngD/PhD, R&D• Focused relevant training to address skills shortages• Education at all stages from school through to advanced researchEducation at all stages from school through to advanced research

Opportunities• R&D across the TRLs• R&D across the TRLs• TSB, EU, EPSRC collaboration• Benefit from the latest technologies and methods• Support new supply chains in the UK for new powertrain technologies• Support new supply chains in the UK – for new powertrain technologies

ExamplesAutomation system design and lifecycle support• Automation system design and lifecycle support

• Prototyping new system layouts and production processes• Safety and security implications of new technology, e.g. Internet-based services


Th k Y !Thank You!Robert Harrison

b t h i @ i k [email protected], Automation Systems Group


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Creating Future Powertrain Manufacturing Capability: An ... · Creating Future Powertrain Manufacturing Capability: An Automation Perspective PfProfessor Rb tRobert HiHarrison Head