RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
From design to production: simulation and
optimisation of the Body in White joining process
Warwick Manufacturing Group
9th December 2014
1
Live web feed via URL
(emailed to all attendees)
Live twitter link
@rlwnavigator
#rlwnav14
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Audience Survey
RLW Navigator Symposium
Survey
4
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Welcome & Symposium
Introduction
Prof. Darek Ceglarek, WMG, University of Warwick, UK
RLW Navigator Symposium
Agenda
9.30 – 9.35
9.35 – 9.50
9.50 – 10.20
Welcome and Symposium Introduction
Overview of HVM Catapult program
Laser Processing for the Automotive
Prof. Darek Ceglarek, WMG, Univ. of Warwick
Dr Alan Curtis, HVM Catapult, Univ. of Warwick
Prof. Richard Dashwood , WMG Academic Director
Dr Andrei Andreev ,Trumpf GmBH
10.20 – 10.35
RLW Navigator Project Introduction
10.35 – 11.00
Coffee and Contacts
11.00 – 11.20
RLW System Configurator
11.20 – 11.40
11.40 – 12.00
12.00 – 12.20
RLW Workstation Design & OLP
RLW Process Optimiser
RLW Process Control
12.20 – 13.00
Lunch
13.00 – 13.15
13.15 – 13.35
RLW Eco Advisor
RLW Navigator NPI Workflow
Prof. Ian Anthony Stroud, EPFL
Charles Marine, Stadco Group
13.35 – 14.20
14.20 – 15.00
15.00– 16.00
WMG Facility Tour
Round Table & Panel Discussion
Summary & Conclusion
Prof. Darek Ceglarek, WMG, Univ. of Warwick
Break & Live Demonstrations
Prof. Darek Ceglarek, WMG, University of Warwick
Antonio Taurisano, EnginSoft S.p.A
Dr. Marcello Colledani, Polimi
Prof. Joszef Vancza, SZTAKI
Dr. Pasquale Franciosa, WMG, Univ. of Warwick
Markus Kogel-Hollacher, Ph.D., Precitec GmBH,
Dr. Pasquale Franciosa, WMG, Univ. of Warwick
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Overview of HVM Catapult
Dr. Alan Curtis, Chief Executive – WMG Centre HVM Catapult,
University of Warwick, UK
Prof. Richard Dashwood - WMG Academic Director,
University of Warwick, UK
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Laser Processing for the
Automotive Industry
Dr Andrei Andreev, Industry Management AutomotiveRemote Applications, Trumpf GmBH, DE
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Introduction
Prof. Darek Ceglarek, WMG, University of Warwick, UK
RLW Navigator Symposium
Remote Laser Welding
•It is a single sided joining process for steel
•It is 5 times faster than Spot Welding
•It is structurally comparable to current processes
•It offers product design opportunities
CHALLENGES
OPPORTUNITIES
•
•
•
•
•
•
•
Faster Processing Speed
Flexible Manufacturing
Fast model changeover
Reduced Floor Space
Lower Investment Costs
Lower Operating Costs
Improved Product Design
•
•
•
•
•
•
•
Process Feasibility
Workstation design
Robot Programming & OLP
Part fit up
Process Monitoring
Process Control
Energy Efficiency
10
RLW Navigator Symposium
RLW Navigator Project Definition
The RLW Navigator Project will provide a software toolkit to facilitate
the process planning, design, implementation and optimisation
in the application of Remote Laser Welding technology in Body In
White sheet metal joining
11
RLW Navigator Symposium
RLW Navigator Project Content
The Path to “First-Time-Right”
12
RLW Navigator Symposium
RLW Navigator Project Development
Exploitation
Industry
Ready
Demonstrator
Analytical
Experiments
Concept
Development
TRL 7-9
TRL 5-6
TRL 3-4
TRL 1-2
13
RLW Navigator Symposium
RLW Navigator Demonstrator
The main purpose of the Demonstrator is to provide a industry
compatible platform to verify and validate the experimental
methods and tools to current industrial standards and to apply
these methods and tools to the Pilot Build of an existing
industrial case study and demonstrate Application Readiness
(TRL 6)
TRL 1-2
TRL 3-4
TRL 5-6
TRL 7-9
14
RLW Navigator Symposium
RLW Navigator Demonstrator
15
RLW Navigator Symposium
RLW Navigator Demonstrator
Comau SmartLaser
IPG 4kW Fibre Laser
Inspection Fixtures
PRIMES Power/Focus
Meter
Metrology
PRECITEC Process
Monitoring
Metallography
Strength Testing
Welding Fixture
Dimpling Fixture
16
RLW Navigator Symposium
RLW Navigator Project Benefits
 GUI based Process Estimator
 R & M based Process Simulator
 Reduced time to deliver Process
Concept
 Early Process and Robot Path
Planning Feasibility
 OLP for Remote Laser Welding
 Workstation Layout
 Robot/Fixture Calibration
 Reduced Robot Programming in
Commissioning/Launch phase
 Virtual “walk-through” of process
based on fixture and robot
optimisation
 Energy Consumption based
on actual Robot Path and
Process content




Process Monitoring for Comau SmartLaser
Process Monitoring software to predict weld performance
Laser Parameter Optimiser to improve Weld Quality
Reduced Weld Quality Loops in Commissioning/Launch
phase
 Early interaction with Product
Design to generate feasible stitch
matrix and 3D clamp design
 Laser Parameter Process Window
for all stack-ups related to weld
performance
 Reduced fixture clamp adjustment
in Commissioning/Launch phase
The Path to “First-Time-Right”
17
RLW Navigator NPI Process
RLW NAV Workflow
Process
Feasibility
System & Workstation
Design
System
Configurator
Workstation
Planner &
OLP
System
Configurator
Process
Control
Workstation
Planner &
OLP
Process
Optimiser
Eco-Advisor
Process
Optimiser
Digital
Visualisation
Process
Feasibility
System & Workstation
Design
Process
Control
Process
Control
18
RLW Navigator Symposium
RLW Navigator Project Content
RLW System Configurator
Antonio Taurisano, EnginSoft S.p.a, IT
Dr. Marcello Colledani, POLIMI, IT
19
RLW System Configurator
Assembly Layout and Process Estimator
What is it?
•
Integrated environment based on a GUI for
fast evaluation of layout feasibility
What does it do?
•
•
•
•
Quick design and editing of Assembly Layouts
Automatic generation of Task Sequencing table
Fast evaluation of main design KPIs
Displays layout, task sequencing and KPIs at a
glance
Benefits
•
•
•
•
•
•
•
Strong reduction of time for line feasibility analysis
Improved feseability evaluation
Easier management of all data needed for line design within
the same GUI
Faster real time evaluation of design KPIs
Fully customizable resources and costs database
Easy management of design constraints
Functionalities for faster reporting
20
Assembly Layout and Process Estimator
Verification & Validation
JLR door test case has been implemented in order to verify the reliability of the tool in terms of GUI
stability and results accuracy
20 entities, 57 operations and 9 stations have been defined in order to study the test case
•
Time to design the line ≈ 4h
•
Time for station definition ≈ 0.5h
STATION 1
•
Results
Components
100 R1 Handling+Welding robot
TurnTable
Safety light
OP1-Operator
Components
Smart Laser-Lase welding robot
TurnTable
STATION 4
Clamping Fixture Complex-AUTO FIXTURE_AUTO CLAMPS
(RLW)
Power Motor
100R1-Handling+Welding robot
Laser Source
REFERENCE VALUES FROM INDUSTRIAL CASE
LAYER 0 RESULTS
DELTA ERROR [%]
WeightingFactor
p with W.F.
r
WeightingFactor p with W.F.
r
WeightingFactor p with W.F.
0.216
0.0002233944 0.2557544757
0.232
0.0002389758 0.2557544757
7.4
7.0
0.080
0.0000200978 0.2508340231
0.080
0.0000200777 0.2508340231
0.0
-0.1
1.000
0.0000491639 0.4637076783
1.000
0.0000491587 0.4637076784
0.0
0.0
0.688
0.0017286432 1.0000000000
0.668
0.0017243108
1
-2.9
-0.3
r
0.0
0.0
0.0
0.0
WeightingFactor
0.757
0.090
0.072
1.000
0.072
1.000
r
0.0
0.0
0.0
0.0
0.0
0.0
p with W.F.
0.0020539980
0.0000226326
0.0000647030
0.0001176987
0.0000745393
0.0027027027
r
WeightingFactor
0.2853585713
0.766
0.2508340231
0.090
0.3338695284
0.072
0.4523977350
1.000
0.2557544757
0.072
0.2000000000
1.000
p with W.F.
0.0020588673
0.0000226100
0.0000645295
0.0001176681
0.0000742391
0.0026666667
r
WeightingFactor
0.2853585713
1.2
0.2508340231
0.0
0.3338695284
0.0
0.4523977350
0.0
0.2557544757
0.0
0.2000000000
0.0
p with W.F.
0.2
-0.1
-0.3
0.0
-0.4
-1.3
21
Assembly Layout and Process Estimator
Software Demonstration
22
RLW System Configurator
Configuration Optimiser
What is it?
•
System-level configuration optimiser, integrated
with performance evaluation modules
What does it do?
•
•
•
•
•
Precise calculation of system performance,
considering resource reliability and buffers.
Multi-objective optimisation on:
 Production and inventory costs.
 Line actual productivity (i.e., OEE and JPH).
 Energy consumption.
 Cycle times.
Generation of a set of optimised candidate
solutions (Pareto frontier)
Robustness and sensitivity analysis
Discrete Event Simulation for candidate solutions
SUMMARY OF CONFIGURATIONS
Benefits
•
•
•
•
•
Fast configuration evaluation, to study more potential configuration in
less time
Actual and detailed line OEE and JPH estimation
Connection with reliability databases
Detailed and customizable output visualiser
Robustness levels for each optimal configuration
PRODUCTIVITY
JLR
TH [PART/MIN]
0,455
ABL(TOT) [PARTS]
3,309
WIP[PARTS]
7,407
JPH[PARTS/HOUR]
27,300
ENERGY
N SPOTS
95
N STICH
0
E PART
427500
E HOUR
11678445
WELDING COST
CW PART [EU/PART]
1,188
CW HOUR [EU/HOUR]
32,440
INVENTORY COST
Ci [EU/HOUR]
0,059
ENERGY COST
Ce [EU/HOUR]
0,648
TOTAL COST [EU/HOUR]
33,148
TOTAL COST [EU/part]
1,213
N° ROBOTS
28
REC 1 REV 1
0,4567
1,4897
5,6
27,402
REC 1 REV 2
0,4555
1,4005
5,5
27,33
0,455
1,505
5,6
27,3
REC 3 REV 1
0,457
1,487
5,6
27,42
REC 3 REV 2
0,4563
1,3833
5,49
27,378
0,4606
3,2862
7,4316
27,636
13
59
176500
4836453
13
59
176500
4823745
13
59
176500
4818450
13
59
176500
4839630
13
59
176500
4832217
14
56
175000
4836300
0,863
23,651
0,861
23,531
0,858
23,418
0,858
23,521
0,858
23,485
0,835
23,075
0,0448
0,044
0,045
0,045
0,044
0,0594528
0,268
23,965
0,875
17
0,268
23,843
0,872
16
0,267
23,731
0,869
19
0,269
23,835
0,869
17
0,268
23,797
0,869
16
0,268
23,403
0,847
17
REC 2
REC 4
23
RLW System Configurator
System-Level Configurator
•
What does it do?
•
•
•
•
•
Component
database
Reliability
database
Early-stage design of assembly systems in a designoriented Graphical User Interface
Integrated definition of task sequencing and layout
Precise calculation of system performance over a large
number of alternative configurations
Multi-objective optimisation on costs, productivity and
number of resources
Robustness analysis and Discrete Event Simulation for
candidate solutions
Transfer functions
Optimal system configuration
Integrated platform for system concept
generation and configuration optimisation
Assembly Layout and
Concept Generator
User input GUI
What is it?
Design input:
o Product information
o Basic features
o Basic KPIs
o Resources
Stations
modelling
Configuration
optimiser
Benefits
•
•
•
•
•
Faster and integrated system design procedure
Fast configuration evaluation to study more potential configuration
in less time (1000 configurations, 30 minutes)
Actual and detailed line OEE and JPH estimation
Connection with reliability and component databases
Detailed and customizable output visualiser
24
RLW System Configurator
Verification & Validation
Validation on JLR industry case
 System Configurator has been used for the optimization of JLR industry case, consisting in 4 different
reconfigurations with hybrid RSW+RLW technologies:
 Process speed (+400%)
 Overall costs (-30%)
 Energy (-60%)
 Floor space (-50%)
 Number of robots (-40%)
Comparison between analytical and DES Simulation
 Provide an estimation of the error incurred by the designer when
using the analytical method
 Maximum error on throughput: 0,4%
 Maximum error on WIP: 1,6%
Validation on other industrial cases

Test System Configurator to be tailored on specific application and layout:
 Case 1: machining and assembly of vehicle engines
 Case 2: body-in-white assembly
Number
of stations
Group of
operations
Intermediate
buffers
Failure
modes
Configurations
Computational
time
Case 1
23
23
22
147
1500
3 hours
Case 2
3
24
2
18
100
7 minutes
Process Simulator
Software Demonstration
26
RLW Navigator NPI Process
RLW NAV Workflow
Process
Feasibility
System & Workstation
Design
System
Configurator
Workstation
Planner &
OLP
System
Configurator
Process
Control
Workstation
Planner &
OLP
Process
Optimiser
Eco-Advisor
Process
Optimiser
Digital
Visualisation
Process
Feasibility
System & Workstation
Design
Process
Control
Process
Control
27
RLW Navigator Symposium
RLW Navigator Project Content
RLW Workstation Design & OLP
Prof. Joszef Vancza, Institute for Computer Sciences and
Control (SZTAKI) , HU
28
RLW Workstation Design & OLP
Workstation Planning & OLP
What is it?
•
A software toolbox that supports the detailed configuration, optimization, automated off-line
programming and simulation of RLW workstations.
What does it do?
•
•
•
•
•
•
Accessibility analysis, feedback to fixture and
product design
Integrated welding task sequencing and robot
path planning for minimizing cycle-time
Collision detection and avoidance
Detailed workstation design
Automated off-line robot code generation
Simulation of the RLW workstation
Benefits
•
•
•
•
Significantly reduced robot programming
effort and time
First-time-right implementation due to
complete calibrated digital model
Shortened ramp-up process and accelerated
time-to-market
Increased throughput and reduced energy
demand
29
Workstation Planning & OLP
Verification & Validation
Computational tests
•
•
•
Real product (LR door) and robot (Comau C4G)
~90 problem instances
Benchmarking against single published method
Test results
•
•
Cycle-time improvement up to 200%
No zig-zaging
Successful physical tests at WMG
1.
2.
3.
4.
5.
6.
Building the model of the workcell
Placement of the fixtures
Calibration
Simulation
Automatic OLP generation
Code execution and measurements
30
RLW Workstation Design & OLP
Software Demonstration
31
RLW Navigator NPI Process
RLW NAV Workflow
Process
Feasibility
System & Workstation
Design
System
Configurator
Workstation
Planner &
OLP
System
Configurator
Process
Control
Workstation
Planner &
OLP
Process
Optimiser
Eco-Advisor
Process
Optimiser
Digital
Visualisation
Process
Feasibility
System & Workstation
Design
Process
Control
Process
Control
32
RLW Navigator Symposium
RLW Navigator Project Content
RLW Process Optimiser
Dr. Pasquale Franciosa, WMG, University of Warwick, UK
33
RLW Process Optimiser
Process Integration Concept
PRODUCT &
PROCESS DATA
DATA
LIBRARY
OPTIMISED
RLW PROCESS
OPTIMUM
CLAMP LAYOUT
PROCESS UNFEASIBLE
MODIFY PRODUCT
OPTIMUM
STITCH LAYOUT
OPTIMUM
LASER PARAMETERS
34
RLW Process Optimiser
Part Variation Modeller
What is it?
•
Software package for virtual modelling of
deformation
patterns
of
sheet-metal
part/assembly
What does it do?
•
•
•
Generates virtual part or assembly based on part
CAD and/or measurement data
Variation Simulation Analysis for deformable
parts
Statistical Process Control (SPC) for surface
measurements (cloud of points data) used in
stamping process or/and assembly
Benefits
•
•
•
Facilitates design optimisation for improved part and
assembly performance
Provides an analysis tool for surface measurements (cloud of
points data) used in stamping process or/and assembly
Facilitates root cause analysis in stamping and assembly
processes
Deviation
[mm]
Deviation
[mm]
Deviation
[mm]
35
RLW Process Optimiser
Fixture Layout Analyser & Optimiser
What is it?
•
Determine clamp location to optimise part to
part fit-up geometry
What does it do?
•
•
•
Definition and application of design locator
strategy
Optimisation of clamp position to satisfy joint fitup geometry
Optimisation of clamp position to satisfy
assembly dimensional quality
•
•
•
•
•
•
Improved interaction between product and process
engineering
Reduced engineering implementation cost
Reduced fixture design time and engineering design
changes
Reduction of fixture content and complexity
Reduction of installation, commissioning and launch
time
Improved assembly quality
Gap [m m ]
Benefits
Sam pling point
36
RLW Process Optimiser
Laser Process Parameter Optimiser
What is it?
•
Determine optimum
parameter selection
laser
welding/dimpling
What does it do?
Definition of optimum process parameters (i.e.,
power, speed), based on defined output criteria:
•
•
Maximum joint quality
Minimum cycle time
Minimum power demand
Automatic identification of feasible process
windows
Allow process optimisation loop with robot
simulation and path planning
Gap [mm]
0.05
0.1
0.2
0.3
1.0
2.0
3.0
4.0
Gap [m m ]
•
•
•
Speed [m/min]
•
Sam pling point
Benefits
•
•
•
•
•
Improved joint quality
Facilitate parameter selection based on process
performance
Reduced engineering implementation cost
Reduced number of process parameter adjustements
Reduction of installation, commissiong and launch
time
37
RLW Process Optimiser
RLW Navigator Test Case Verification & Validation
Tool
Result %
Measurable result
Fixture Layout Analyser
& Optimiser
Laser Process Parameter
Optimiser
Coupon trials
Door assembly
NA
(65/72) - 90%
(245/250) - 98%
(61/72) - 85%
Percentage of stitches* with satisfactory gap
(based on predicted clamp location)
Coupon trials: percentage of welding trials* with
predicted error below 10%
Door assembly: percentage of satisfactory
stitches** (based on predicted parameters)
*Number of coupon trials = 250 - **Total number of stitches on door assembly = 72
Stack-up 1
1.40
1.20
1.20
1.00
1.00
0.80
0.60
0.40
0.40
0.20
0.00
TC
BC
Penetration
B-width
Stack-up 2
Predicted KPI
Predicted KPI
1.20
KPI value [mm]
KPI value [mm]
1.40
1.00
0.80
0.60
0.40
0.20
0.00
S-value
TC
S-value
TC
BC
B-width
Stack-up 4
Experimental KPI (average)
1.60
Penetration
Stack-up 3
0.60
0.00
S-value
Experimental KPI (average)
0.80
0.20
Penetration
Stack-up 1
Stack-up 3
Predicted KPI
Experimental KPI (average)
KPI value [mm]
KPI value [mm]
Predicted KPI
BC
B-width
Experimental KPI (average)
1.60
1.40
1.20
1.00
0.80
0.60
0.40
0.20
0.00
Stack-up 4
Penetration
S-value
TC
BC
B-width
Stack-up 2
38
RLW Process Optimiser
Software Demonstration
39
RLW Process Optimiser
Process Integration Concept
PRODUCT &
PROCESS DATA
DATA
LIBRARY
OPTIMISED
RLW PROCESS
OPTIMUM
CLAMP LAYOUT
PROCESS UNFEASIBLE
MODIFY PRODUCT
OPTIMUM
STITCH LAYOUT
OPTIMUM
LASER PARAMETERS
40
RLW Navigator NPI Process
RLW NAV Workflow
Process
Feasibility
System & Workstation
Design
System
Configurator
Workstation
Planner &
OLP
System
Configurator
Process
Control
Workstation
Planner &
OLP
Process
Optimiser
Eco-Advisor
Process
Optimiser
Digital
Visualisation
Process
Feasibility
System & Workstation
Design
Process
Control
Process
Control
41
RLW Navigator Symposium
RLW Navigator Project Content
RLW Process Control
Markus Kogel-Hollacher Ph.D., Precitec Optronik GmBH, DE
Dr. Pasquale Franciosa, WMG, University of Warwick, UK
42
RLW Process Control
Process Monitoring
Concept Design
What is it?
•
Sensor hardware integrated into the Comau SmartLaser robot
as first in-axis solution
What does it do?
•
•
Integrates state-of-the-art sensor technology into the
Comau SmartLaser robot
Enables the in-process and in-situ acquisition of the
desired quality information to evaluate the current quality
status
Installation
Benefits
•
•
•
The current system can be used at the commissioning and
production stage of NPI for statistical process control, Root
cause analysis (RCA), and process adjustment
Retrofit of all existing Comau SmartLaser robots
Fully implemented sensor technology for Process
monitoring/ control enables continuous compliance to the
specific quality standards and improve decision making
processes
Back reflection
Plasma
Temperature
43
RLW Process Control
Weld Quality Performance Evaluator
Data Monitoring
What is it?
•
Software package for estimation of joint performance (i.e., penetration
and s-value) using in-line process monitoring data
What does it do?
•
•
•
It
takes
the
most
relevant
KPIs
in
remote laser welding and relates them with the signals
extracted from the processing area
Direct output of weld quality reduces operator’s interpretation
errors
Closed-loop process adjustment based directly on weld quality
is achievable
Welding process parameters can be optimised for a specific
performance output
Model Development
Rep. 1
Gap [mm]
0.05
0.1
0.15
0.2
0.25
0.3
0.4
1.0
Speed [m/min]
•
2.0
3.0
4.0
No WELD
Benefits
•
•
•
•
In-process weld analysis reduces NDT and destructive
testing
Use of analytical mathematical model automatically
linking monitoring data to joint performance
Facilitate Statistical Process Control and root cause of
joint failure
Capability for in-line closed loop process control and
adjustment
44
RLW Process Controller
Verification & Validation
Tool
Measurable
Result %
Process Monitoring
Installation of in-axis monitoring system for
COMAU SmartLaser
Installed & Tested
Weld Quality Performance
Evaluator
Percentage of welding trials* with predicted
error below 10%
(56/60) - 93%
*Total number of welding trials = 60
Main achievements
•
•
Predicted S-value (Average)
Good agreement between predicted and
measured KPIs
S-value has high correlation to signal data
(plasma, temperature and back-radiation)
Measured S-value (Average)
16.00%
2.2
speed=2m/min
speed=3m/min
14.00%
speed=4m/min
12.00%
1.8
1.6
1.4
speed=1m/min
Error [%]
KPI value [mm]
2
10.00%
8.00%
6.00%
4.00%
2.00%
1.2
1
0.00%
45
RLW Process Controller
Software Demonstration
46
RLW Navigator NPI Process
RLW NAV Workflow
Process
Feasibility
System & Workstation
Design
System
Configurator
Workstation
Planner &
OLP
System
Configurator
Process
Control
Workstation
Planner &
OLP
Process
Optimiser
Eco-Advisor
Process
Optimiser
Digital
Visualisation
Process
Feasibility
System & Workstation
Design
Process
Control
Process
Control
47
RLW Navigator Symposium
RLW Navigator Project Content
RLW Eco – Advisor
Prof. Ian Anthony Stroud, EPFL, CH
48
RLW Eco Advisor
Eco-advisor Software
What is it?
•
Welding eco-effects calculator
What does it do?
•
•
•
Estimates energy used for welding
Animates given path to show robot movements
Calculates energy for robot movement calibrated
by experiments
• Calculates energy for laser based on stitch data
• Calculates energy for auxiliary equipment based on
• overall time
Benefits
•
•
•
•
•
Ability to foresee effects of different welding strategies
Quantification of effects based on theory and experiments
Component for factory planning
Theoretically and experimentally based
Separation of contributing factors for more
complete understanding
49
RLW Eco Advisor
Verification & Validation
Verification and validation
•
•
•
Experiments to measure laser power in welding
Experiments to measure real welding path for comparison with theoretical power use
Calculation of power loss in motors as a multiplication factor for software
Comparison of power consumed by Mechanical Movement
Sl. No
Power consumption in KWh
Experimental
Computational
Description
1
0.02
0.02
71 Stitches
2
0.007
0.006
Stitches 1 - 23
3
0.0074
0.007
Stitches 24 - 45
4
0.0077
0.007
Stitches 46 - 71
50
RLW Eco Advisor
Software Demonstration
51
RLW Navigator Symposium
RLW Navigator Project Content
RLW Navigator NPI Concept
Charles Marine, Stadco Group, UK
52
RLW Navigator NPI Process
Traditional BIW NPI Process
Order Acquisition
Engineering
Concept
3D Design
Installation &
Commissioning
Manufacture & Assembly
Launch
Production
2D Design
Robot Simulation
Release
Release
to
Engineering
•
•
•
•
•
Proposal Development
Estimating
Submission
Nomination
Project Handover
Process
Feasibility
to
Manufacture
•
•
•
•
•
Concept Feasibility
3D Design
2D Design
Robot Simulation
System Layout
OK to Ship
•
•
•
•
Manufacture
Build
Inspection
Validation
System & Workstation
Design
Ready for Launch
•
•
•
•
Site Preparation
Installation
Commissioning
Preliminary Acceptance
Ready for Job1
•
•
•
•
•
•
Quality Loops
Weld Quality
Dimensional Quality
Cycle Time
Process Capability
Final Acceptance
•
Process Monitoring
Process
Control
53
RLW Navigator NPI Process
RLW NAV NPI Process Concept
Commercial
•
RFQ
•
Product Data
•
Prod’ Data
Design
• Product
• Build
• Locators
• Tolerances
Concept
3D
Design
System
Configurator
Process
Feasibility
Stamped Parts
Q Loop
Process
Optimiser
Process
Optimiser
Workstation
Planner &
OLP
Workstation
Planner &
OLP
Process
Control
Process
Control
Stamped Parts
Production
2D Design
System
Configurator
Order Acquisition
Stamped Parts
Q Loop
Process
Optimiser
Process
Optimiser
Workstation
Planner &
OLP
Workstation
Planner &
OLP
Eco-Advisor
Digital
Visualisation
Engineering
System & Workstation
Design
Workstation
Manufacture &
Assembly
Manufacture &
Assembly
Installation &
Commissioning
Launch
Process
Control
Process
Control
Production
54
RLW Navigator NPI Process
RLW NAV NPI Process Concept
Commercial
•
RFQ
•
Product Data
•
Prod’ Data
Design
• Product
• Build
• Locators
• Tolerances
3D
Design
Concept
Stamped Parts
Q Loop
Stamped Parts
Q Loop
Stamped Parts
Production
2D Design
System
Configurator
System
Configurator
Process
Estimator
Process
Estimator

Process Concept

Process Cost

Process
Simulation
Robot
Clamp
Simulation Feasibility
Process
Parameters
Process
Feasibility
Robot
Access
Robot
Clamp
Simulation Feasibility
Process
Parameters
Robot
OLP
Workstation
Manufacture &
Assembly

Stitch Matrix

Clamp Matrix

Workstation
Placement

Laser
Parameter
Matrix

Robot
Simulation

Stitch Matrix

3D Clamp Matrix
DESIGN
FEASIBILITY

LOOP
Weld KPI’s


Laser Parameter
Matrix

Robot
Simulation/OLP
Robot
Clamp
Simulation Feasibility
Robot
Access
Process
Parameters
Weld Quality
Cycle Time
Robot
OLP

Weld Quality
Weld KPI’s
Weld KPI’s
Workstation
Placement

Process
Parameters
Robot
Clamp
Simulation Feasibility
Process
Parameters

Order Acquisition
Robot
Calibration

QUALITY
FEASIBILITY
LOOP


Cycle Time
Weld Quality
Cycle Time
System
Simulation
Engineering
System & Workstation
Design
Manufacture &
Assembly
Installation &
Commissioning
Launch
Process
Control
Production
55
RLW Navigator NPI Process
NPI Feasibility Process Comparison
Engineering
Manufacture &
Assembly
Installation &
Commissioning
Launch
Production
Feasibility
Order Acquisition
Order Acquisition
Engineering
Manufacture &
Assembly
Installation &
Commissioning
Launch
Production
Current RLW Process
RLW NAV Process
56
RLW Navigator NPI Process
NPI Feasibility Process Comparison
Current RLW Process
RLW NAV Process
Engineering
Manufacture &
Assembly
Installation &
Commissioning
Launch
Production
Feasibility
Order Acquisition
Manufacture &
Assembly
Installation &
Commissioning
Order Acquisition
Engineering
Launch
Detailed Process
Concept
Reduced Design Time
Reduced Fixture Adjustment
Optimised Process
Reduced Weld Optimisation
Production
Reduced Robot Programming
Predictive Weld Quality Monitoring
57
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
WMG Tour
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Audience Survey
RLW Navigator Symposium
Survey
60
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Round Table and
Panel Discussion
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Summary & Conclusion
RLW Navigator
Remote Laser Welding System Navigator for
Eco & Resilient Automotive Factories
Live Demos