Island life
The SmartFactory KL e. V. technology initiative and the German Research Center for Artificial Intelligence (DFKI) are joining forces with 18 partner companies to showcase the latest version of their Industry 4.0 plant in Hannover. The plant’s modules are no longer arranged in a series but for the first time are distributed between three production islands.

The extended demo plant from the SmartFactoryKL partner network, which is essentially based on the three standards "RFID tag description", "OPC UA communication" and "hardware standardization", is being exhibited in a new layout and uses a flexible transportation system. As this system’s central elements are a robot platform and conveyor belts in the modules, the product - a customized business card holder - can be manufactured in various ways. This means production does not need to be tied down to one particular location. Once the product has been machined according to the relevant standards, the Manufacturing Execution System (MES) decides in the four modules where the product is to be transported for further processing, based on a notification issued by the integration bus via the plant topology.

Although the flexible transportation system is only moving the product around within a small area at HANNOVER MESSE 2017, it quickly becomes clear that, in real-life applications, this approach can be applied to different production lines, factory facilities or even separate locations. The product finds the correct module for the next processing step because it controls its decision cycle via the memory on the RFID tag and is guided by the IT structure used.

"We have the roundtable partnership involving industry and science to thank for this new application. It is because the partners collaborate on a level playing field, in keeping with the spirit of our initiative, that we have been able to successfully explore new research topics," says Prof. Detlef Zühlke, CEO of SmartFactoryKL and head of the Innovative Factory Systems research group at the German Research Center for Artificial Intelligence (DFKI). The partner companies for the SmartFactoryKL Industry 4.0 plant include Belden/Hirschmann, Bosch Rexroth, CISCO, EPLAN Software & Service, Festo, HARTING, IBM, iTAC, LAPP KABEL, Mettler Toledo, MiniTec, PHOENIX CONTACT, Pilz, proALPHA, TE Connectivity, TÜV SÜD, Weidmüller and Wibu-Systems.
SmartFactory-KL e.V. technology initiative (67663 Kaiserslautern, Germany), Hall 8, Stand D20
Contact: Dr. Haike Frank
Tel.: +49 631 20575 3406
Fax: +49 631 20575 3402
E-Mail: frank@smartfactory.de

"We'll find our own way" - ever heard that from your components?
In the future, every component will be able to find its way independently through the process chain and tell machinery what needs to be done. The Fraunhofer Institute for Production Technology IPT is showing just how this can be achieved at HANNOVER MESSE 2017.

Nowadays, for example, engine blocks are generally manufactured by a number of machines in interlinked processes. All the operations are precisely defined in a kind of roadmap. The problem is that if machines fail or components need to be prioritized due to customer needs, there is a lack of flexibility. Researchers from the Fraunhofer Institute for Production Technology IPT are therefore showcasing a production system at HANNOVER MESSE 2017 in which each component carries with it information about the production steps it needs to go through, so that it can orient itself like an individual.

The components, which each have a QR code, are thus able to select the first available machine with the appropriate capabilities for each individual processing step. As the components pass through each production stage, the system identifies which task has been completed and to what extent and the software thus records the production history for each component, creating a digital twin. The developers of this system have dubbed it a "service-oriented architecture for adaptive and networked production".

Thanks to the digital twin, the system knows at all times what is being machined, what is doing the machining and what the next step is. Companies whose machinery produces batches of different components can benefit greatly from this innovation. Unlike conventional manufacturing with systems that have to be halted, reprogrammed and converted when switching to the new product, the Fraunhofer researchers' service-oriented solution has the product itself telling the machinery what needs to be done. "By networking components and machines, companies in the future will be able to manufacture truly unique products one after another, thus achieving batch size 1 production," explains Michael Kulik, project manager at the IPT. To do that, companies will have to ensure all the process data for the relevant component can be provided in the form of a digital twin in a smart manufacturing network.
Fraunhofer Institute for Production Technology IPT (52074 Aachen, Germany), Hall 17, Stand C18
Contact: Susanne Krause
Tel.: +49 241 8904-180
Fax: +49 241 8904-6180
E-Mail: presse@ipt.fraunhofer.de

Damping everything - except your enthusiasm!
Damping technology specialist ACE is showcasing a range of trade fair debuts in Hannover this year - including its extensive portfolio of innovative safety products.

In terms of basic physical parameters, damping technology essentially transforms kinetic energy into heat. However, this seemingly straightforward process is only half the story. In fact, damping solutions make machines faster, quieter, lighter, more efficient and more durable - and thus more competitive and profitable. Crucially, machines equipped with damping technology are also safer. The German division of internationally renowned damping technology specialist ACE (established in Langenfeld in 1978) is at HANNOVER MESSE 2017 with an extraordinarily extensive portfolio of industrial shock absorbers, gas springs and vibration technology, including its ingenious safety innovations.

This special line of ACE products is designed to safely slow down the potentially damaging forces of moving loads and, when it comes to the crunch, activate emergency braking if need be. ACE offers an astonishingly wide range of safety shock absorbers, profile dampers and clamping elements, with each safety component specifically developed for a precise application. This meticulous design process is particularly crucial in emergency stop functions. Given the protection they deliver, ACE safety solutions are exceptionally cost-effective, and are easy to integrate into existing designs in almost every conceivable application. What’s more, they are extremely low-maintenance and generally do not even require their own energy supply.
ACE Stossdämpfer GmbH (40764 Langenfeld, Germany), Hall 16, Stand F07
Contact: Jörg Küchmann
Tel.: +49 2173 9226-4233
E-Mail: j-kuechmann@ace-int.eu

PSI showcases integrated manufacturing scenario
PSI subsidiary PSI Automotive & Industry GmbH is exhibiting an integrated production scenario at HANNOVER MESSE 2017 based on various PSI software modules.

The ever-present push toward digitalization is making quite an impact, with HANNOVER MESSE 2017 once again showcasing a record number of specific applications for advanced Industry 4.0 technologies. One example comes courtesy of PSI Automotive & Industry GmbH, a subsidiary of Berlin-based PSI AG, which is exhibiting an integrated production scenario in Hannover. This scenario comprises dynamic production planning and control that has been developed using PSI products from various areas. Another practical example demonstrates very clearly how cutting-edge IoT and RFID technology can be implemented, while comprehensive logistics and network solutions from the PSI sectors of production, logistics and energy are also on show.

Finally, the complete scenario at the trade fair is controlled by various PSI software modules that handle even complex processes and problems in real time, thus delivering sustained increases in production efficiency. The scenario is adapted to the production requirements of engineer-to-order (ETO), make-to-order (MTO) and series production, which makes it particularly flexible. In fact, it also takes into account last-minute customer requirements with high levels of personalization and product diversity. The solution supports KPI-optimized production planning and sequencing, ensuring versatility and autonomy for future production systems, such as swarm manufacturing, for specified processes.
PSI Automotive & Industry GmbH (10178 Berlin, Germany), Hall 7, Stand A24
Contact: Manuela Tröger
Tel.: +49 30 2801-2125
Mobil: +49 172 231 28 49
Fax: +49 30 2801-1042
E-Mail: mtroeger@psi.de

From design concept to prototype
Stratasys GmbH, a market leader in additive manufacturing and 3D printing, is celebrating the German launch of its innovative F123-series 3D printers and showcasing new materials for PolyJet and FDM technologies at HANNOVER MESSE 2017.

The umbrella term "rapid prototyping" covers various technologies that convert CAD data directly into prototypes as quickly as possible and without manual intervention or modeling. These manufacturing processes also include Fused Deposition Modeling (FDM), where the workpiece is developed layer by layer from a meltable plastic - a process more commonly referred to as 3D printing. At HANNOVER MESSE 2017, Stratasys - a market leader in additive manufacturing and 3D printing - is showcasing cutting-edge 3D printing solutions, including the new F123-series 3D printer, which is having its German trade fair premiere. Stratasys is also exhibiting advanced materials for PolyJet and FDM technologies that are currently being launched onto the market, and much more besides.

However, the main focus is on the new 3D printer series. Visitors to the Stratasys stand can find out how the professional, all-in-one F123 prototyping systems are set to help simplify the entire prototyping workflow in the future. The new 3D printer series enables designers and engineers to meet the requirements of a wide range of prototyping applications, from concept verification and design validation to functional testing. The user-friendly F123 series is also compatible with GrabCAD Print software. It thus enables users to rapidly produce cost-efficient prototypes for a whole host of key industries, including the consumer goods, aerospace and automotive sectors.
Stratasys GmbH (77836 Rheinmünster, Germany), Hall 6, Stand K06
Contact: Melissa John
Tel: +44 1737 215200
E-Mail: melissa.john@incus-media.com

For photos and video clips, visit: Product Innovations