TISAT4IPP
OPEN CALL 1 | INNOVATION SUPPORT
Name: Threaded Insert Smart Assembly Tool for Industrial Production Process.
Flexible manufacturing systems (FMS) | Energy efficiency | Decision support systems | Predictive maintenance
Abstract: The TISAT4IPP project is related to the development of a specific tool used to process the thread inserts.
The main objective is to develop a smart tool:
• Able to be connected to other tools present in the system/production environment to improve the production quality aspects and the system automation level.
• That is easier to be used by any operators.
It represents the solution to quality, connectivity, and reliability problems of standard hydraulic-pneumatic tools in modern production process.
By design, it is equipped with an electronic board with a microcontroller, a communication port and sensors, catching data from the field during the work and during each working cycle. Thanks to the integrated position and pressure sensors the smart tool can elaborate and check the deformation of each threaded insert. Through the communication port, the data are sent to the host PC or directly to the automation management system. From the data collected is possible to check the quality of each deformation, and eventually notifying the possible problem to the operator.
From the host PC, the collected data can be sent to the cloud and stored in a database. From the cloud data storage is possible to elaborate metrics, statistics and quality checks. Not only the data from the threaded inserts are sent to host PC, but even the data from the machine itself can be sent to the central server. For each produced/sold machine a digital twin model is built. By taking into account simple parameters like worked hour, battery voltage, deformed threaded insert, motor speed, ambient temperature a maintenance model of the tool can be generated, and prognostic can be implemented.
The target for the project is to reach a TRL7 level for the whole tool at the end of this project, testing the tool in the project partner (NDA) production environment, acquiring the data and checking the process from the cloud. The actual stage of the smart tool development is TRL6 for what concern the mechanics, hydraulics, pneumatic systems and mechanics. Several threaded insert deformations have been performed at laboratory level to validate the key components and the design.
The tool design and concept itself is innovative, joins together the idea of an old pneumatic tool with electronics, energy recovery, battery and industry 4.0 concept of quality, maintenance, process optimization, cloud data and prognostics. The use of an energy recovery system (electric motor plus battery) solves the challenge of electronic control in an environment where there is no possibility of electric connection so, the tool can be easily used in existing production lines without any changes since it uses only pneumatic connection. Quality check and IoT can be implemented in existing environment.
The quality check and the prognostic designed in the smart tool are implemented for the first time in a similar type of tool, there is even the threaded insert batch day by day tracking, so the standardization of quality is no more demanded to the operator.
Specialinsert is one of the major players in mechanical fastening solutions for almost 50 years, also customized according to customer needs, suitable for various application sectors: tubular sheet metal, mechanical and plastic components, wood, stone and marble and new composite materials. Due to the breadth of the catalogue the Specialinsert client belongs to all industry sectors. The customers for the smart tool are the actual threaded insert customers. The bigger clients with huge production line (like automotive one) will benefit of the remote control features for assembly line processes. The smaller clients will be attracted by this product by the possibility to guarantee the high-quality standard that the tool can offer.
Main applicant
- Name: FLAG-MS S.r.l.
- Country: Italy
Second applicant
- Name: Specialinsert
- Country: Italy
Industrial partner
- Name: NDA S.r.l.
- Country: Italy
