BEAUTYBEnding AUtomation TYcoon

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The opportunity

TETRA Industriservice Group have been approached by several potential customers in search for a supplier of custom-design bent metal components, such as steel yacht railings or aluminum frames for kitesurfing
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The process

Bending a metal pipe in order to shape a custom-design element.

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The experiment’s goals

to automate fully manual production proces,
to prove that with equipment worth 80k euro we are able to perform 400k euro worth task.

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The concept of the station

  • „Automated” bending machine
  • „Automated” band saw
  • Laser scanners
  • Light curtains
  • RFID reader
  • Industrial robot arm

Challenges:

traceability
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repeatability
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no room for correction (deterioration of material)
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traceability
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repeatability
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no room for correction (deterioration of material)
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lot-size-one
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as cheap as possible (improvements of existing, manual machines)
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generic approach
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New hardwareintegration

  • the industrial robot The interface will be provided via a dedicated ROS module directly communicating with the FlexBe task supervisor,
  • the bending machine. A middleware client and an appropriate interface will be developed to communicate with the machine,
  • the automated saw machine. An appropriate interface will be developed and connected to a dedicated middleware client,
  • the laser scanners and light curtains that will be connected to the local safety component via PLC interfaces,
  • the RFID readers used for retrieving the part specification from the products database.
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Configurationtask

  • modelling the manufacturing process in MPMS,
  • configuring the local safety module to use the laser sensors used and to deal with the proposed layout of the work cell,
  • configuring and training the global awareness component to properly recognize faulty situations in the process,
  • development of new middleware clients providing communication between the system and the newly integrated hardware components,
  • modelling the individual tasks, such as the pipe handling, in the FlexBe task supervisor.
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HORSE Components to be used

  • MPMS – Modelling of manufacturing proces including:
    - allocation of individual tasks to the agents,
    - exeptions handling.
  • Hybrid Task Supervisor – Responsible for synchronizing the execution by several agents (human, robot, machines),
  • Global Awareness Component – through constant monitoring of crucial production parameters provides ways to deal with unexpected downtimes of production line,
  • Local Safety Guard Component – Detecting intrustions in potentially dangerous zones of the production line,
  • HORSE-ROS Bridge – will be used to connect the robot to the task supervisor and control the robot using ROS,
  • HORSE middleware – connecting all used components.

This project has received funding from the European Union’s Horizon 2020research and innovation programme under grant agreement No 680734

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Learn moreAbout CMBIT

  • automation integrator with over 10 years of experience,
  • variety of industrial branches like food processing, waste treatment, machining, etc.,
  • Its expertise spreads from electrical installations through automation equipment programming ending up in area of production management including custom build systems.
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Learn moreabout Tetra Industriservice

  • equipment producer founded in 1999,
  • cooperated with many companies across the Europe, delivering high quality steel and aluminum assemblies,
  • full production installations in dairy, pharmaceutical and brewery for biggest companies in Europe.
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