Completed Projects

• Developed digital die design system for sheet metal forming
• Developed “Spring-back (2D) evaluation method” and “Surface strain evaluation method” to quantify evaluation. (Preamble for 3D methods)
• Evaluated different models and selected the best model for predicting spring-back
• Discussed the role and future research needed to understand the influence of friction and itsrepresentation in simulation.

Advanced Environmental Monitoring System for Production Facilities (IMS # 00001)
New integrated groundwater monitoring system based on innovative technologies.
- Novel biosensors for environmental applications
- Telemetry with a multi-user interface, enabling a new approach to groundwater monitoring in high-tech industries
- Decision-making software for systematic and dynamic planning of work to control groundwater quality

• Developed a means of stimulating the creation of innovative ideas and collecting them from people involved with the products and processes.
• Developed a method for processing ideas and storing them into a structured knowledge repository.
• Developed a means of analyzing innovative knowledge to determine which is useful, and which is not in order to enable the viability of ideas to be assessed.
• Developed the best means of delivering the innovative ideas to product and process designers for maximum effect.

AMITERM - Development of Advanced Microwave and Light-weight High-speed Thermo-response Mould Technology for Woven Textile-reinforced Thermoplastic Components (IMS #00003)
- Developed two new mould technologies for thermoplastic composite parts which allows for high-speed
production
- JETex-Process developed for low-viscous pre-polymers uses dynamic heating for polymerization
- HTex-Process developed for high performance materials which are heated and compressed forming a thermoplastic composite.

CHEM - Advanced Decision Support System for Chemical/Petrochemical Manufacturing Processes (IMS #99002)
- Developed Decision Support System (DSS) for process monitoring, data and event analysis, and
operations support in chemical and petrochemical process plants
- Simulation toolboxes were developed to improve operations
- Developed tools should reduce pollution and accidents

- Developed toolbox to coach SMEs for coaching oriented business process re-engineering/improvement
- Toolbox helps select the most appropriate methodology with regard to their actual business situation and
objectives
- Available at “no charge” to SMEs at http://www.cost-worth.net

Eco-Efficient and High Performance Hard Chrome Process (IMS # 01004)
Develop an environmentally and economically acceptable process for harder, thick, corrosion- resistant coatings of chromium.

- Present guarantees of safety towards employees and environment
- Present performances comparable to dry techniques (projection, PVD, ionic nitruration, etc.)

EFSOT - Next Generation Environment-Friendly Soldering Technology (IMS #01011)
- Developed next-generation technology through evaluation of different solder formulas
- Evaluation included a “total impact assessment” of four formulas
- Recommendations were given for use of solders

Intelligent Manufacturing of E-Music: A Musical Application Standard Using the XML Language for Intelligent Manufacturing of Music for CDs, DVDs, Web (IMS #02002)

Develop IEEE Standard P1599 to combine listening, visual, and intellectual experience under one software tool.

- P1599 considers a musical structure to consist of different layers, each of which represents an aspect of the piece
- Built at the University of Milan’s Laboratory for Musical Informatics, this browser application illustrates the power of the standard and how it works
- Provides an enabling technology that can serve as the basis for realizing an unending stream of new applications

GEM - Global Education in Manufacturing (IMS #01010)
- Researched and defined the needs of the manufacturing industry for training and education in
manufacturing strategy on a global basis
- Developed curriculum to comply with the concept of digital business and extended products
- Developed a framework (detailed specifications) for a manufacturing strategy curriculum focusing both
manufacturing and business administration topics

- Established a set of software standards to allow various pieces of Computer Aided Process Engineering
(CAPE) software used in chemical manufacturing to communicate with each other.
- Established guidelines on how to integrate software.
- Developed software prototypes of simulation software.
- Established the self-funded CAPE-OPEN Laboratories Network (Co-LAN) to manage and advance the
standards.

- Developed a virtual manufacturing environment to reduce lead times from production line planning to
design and production
- Developed distributed autonomous manufacturing technology for flexible manufacturing
- 14 demonstrators developed
- Businesses are changing their business practices as a result of the project.

GLOBEMEN - Global Engineering and Manufacturing in Enterprise Networks (IMS #99004)
- Builds on the completed GLOBEMAN 21
- Management of globally distributed manufacturing businesses
- Produced guide that describes global and dynamic IT infrastructures and encourages industry and
vendor development

GNOSIS - Knowledge Systematization; Configuration systems for Design and Manufacturing (IMS #95004)
- Enables new forms of highly competitive manufactured products and processes which are environment-
conscious, society-conscious and human-oriented.
- Used to design of next generation apartments and environmentally conscious factories.
- Used to enhance ecological designs.
- Improved logistics and speed up the design-to-market flow
- Improved the configuration process for customized products and production.
- Used to test new tools and application areas.

HARMONY - Coping with the Complexity of Business Innovation (IMS #97008)
- Developed a business incubator for SME business innovators
- Articulates SME business plans for to key stakeholders and potential investors
- Includes commercialization and networking tools
- Project harvested new self-sustaining business entity: Harmony Solutions www.Harmony-Solutions.net

HIPARMS - Highly Productive and Re-configurable Manufacturing System (IMS #97004)
- Developed Agile Manufacturing System
- Reduced non-processing time
- Developed reconfigurable tools
- Developed high-speed cutting process

HMS - PHASE I - Holonic Manufacturing Systems (IMS #95003)
- Developed discrete, continuous and batch manufacturing systems using reusable modular design.
- Developed intelligent modules that reconfigure based on demand
- Developed adaptive systems which can “plug and play”
- Provides capability to integrate manufacturing and supply chains
- Offers a migration path from legacy systems to fully distributed manufacturing systems

HUMACS - Organizational Aspects of Human-Machine Coexisting System (IMS #96003)
- Developed “Info-Ergonomics”
- Developed bone-based human model for 3-D ergonomic studies
- Established human-oriented production systems to reduce labor accidents and health damage

HUTOP - Human Sensory Factor for Total Product Life Cycle (IMS #97002)
- Development of working optimization based on human factor for working evaluation system in human-oriented production
- Computer Graphics and Visual Recognition technologies developed to reduce development costs
- Developed new product life cycle concept “HUTOP Cycle”

IF7 - Phase I and II - Innovative and Intelligent Field Factory (IMS #96009)
- Researched assembly methods for large-scale structures, like houses, ships, etc.: From “construction”
to “manufacturing”
- Mechanization systems for assembly of large-scale structures
- Application of autonomous agent to construction management in field factory
- Construction of database to manage parts

INCOMPRO - Intelligent Composite Products (IMS #96008)
- Global, systematic refined solutions for the design and production process based on product morphology
analysis
- Detailed evaluation and analysis related to production method of composite materials
- Personalization/development of software tools for finite element analysis of composite materials
- FEM simulation results matching, sensitivity analysis of FEA/FEM data obtained by practical laboratory
experiments
- Development and improvement of production processes for all project partners
- Systemization and exploitation of composite technical knowledge

INTELIWD - Intelligent Manufacturing of Wood Products Using Color, X-Ray, and Computer Tomography-Based Quality Control (IMS #98006)
- Treats wood as a precious raw material
- Developed comprehensive on-line quality inspection system
- Moved from 2-D visual inspection to 3-D mechanical inspection
- From appearance grading to strength grading

IRMA - A configurable Virtual Reality System for Multi-Purpose Industrial Manufacturing Application (IMS #97007)
- Integrates research and developments in VR, Simulation, CAD, etc., to create a suite of technology
solutions for the Total Life Cycle modeling of the Industrial Enterprise.
- Developed and demonstrated computer based VR systems for improving the factory operations of
Process and Product Design, Plant Monitoring and Control and Training.
- Addresses the organizational and personal issues relating to methods for improved training, working
conditions, effects on the environment, skills, etc., through the application of VR technology.

MISSION - Modeling and Simulation Environments for Design, Planning and Operation of Globally Distributed Enterprises (IMS #97001)
- Supports the Manufacturing System Engineering (MSE) process by integrating modeling and simulation platforms
- Supports engineering and systems integration
- Allows sharing of information generated by any one component amongst all components that may have an interest in that information

- Researched metamorphic material handling systems which respond to varying demands in a flexible manufacturing system.
- Developed prototype automatic guided vehicle (AGV) and support software
- Method of Path-planning/Guide-planning proposed in WP2 and WP3 will raises efficiency of  manufacturing systems.

NGMS - PHASE 1 - Next Generation Manufacturing Systems (IMS #96002)
- A blueprint for the integration of future manufacturing systems into the new forms of manufacturing
enterprises.
- Competitive advantage from a more rapid adoption of advanced systems, processes and technologies.
- More rapid and “right first time” establishment of manufacturing processes and networks of autonomous units through the application of new types of simulation methodologies and tools.
- Greatly improved response times to changing customer needs through the adoption of new forms of modeling and simulation systems.
- Defined the scope of the “Digital Factory” concepts
- Developed an integrate-able set of models and simulators merging a bottoms-up view of the factory floor as found in NGMEs with a top-down view of the globally distributed virtual enterprises

PABADIS - Plant Automation Based on Distributed Systems (IMS #99009)
- Developed “Plug and Participate” IT infrastructure from the enterprise level down to the shop floor
- Combines Java-based Jini technology with mobile and residential software agents
- Minimizes time for set-up of new machines
- New methods in job control enhance efficiency

Product Lifecycle Management and Information Tracking using Smart Embedded Systems (IMS #01008)
Enable the seamless flow, tracing and updating of information about a product, after its delivery to the customer and up to its final destiny (EOL scenario) and back to the designer and producer

- Use, Service and Maintenance or MOL and EOL
- Feedback of information from these phases to BOL (Design and Production).

REMUNE - Advanced REal-time Multi-media and Networking Execution platform and Development Environment

ROBUST - Systematization of Quality Engineering and Software Development (IMS #97009)

Rapid Product Development (IMS #96005)
Accelerate the product development by shortening the respective process chain, providing parts made of production materials and offering an increased flexibility in tooling technology.

- Realisation of software tools for substantially improving process chains starting with physical or digital models of the product and leading to validated physical parts (see Fig. 1.1).
- Development of technologies to rapidly produce parts with mass production materials in small or medium sized series using innovative tooling technologies.

THIS PROJECT HAS COMPLETED. NO FINAL REPORT WAS SUBMITTED.

SIMON - Sensor Fused Intelligent Monitoring System for Machining (IMS #96001)
- Developed on-line calibration and optimization of machining process during prototype machining.
- Developed in-process detection of tool wear and breakage to reduce down time and scrap rate.
- Developed in-process compensation of work-piece and tool deformations for precision machining.

Self-learning Model for INtelligent Predictive Control System for Crystallization PROcesses (IMS #01006)
Drastically increase the efficiency and effectiveness of crystallization processes in the chemical and pharmaceutical industry

- A tool for the rigorous and hybrid modeling of crystallization processes that can be used (a) for parameter estimation (b) for optimization of design and operation (c) starting point for model-based control applications;
- An observer/feedback system based on hybrid models made of a rigorous mechanistic model and an empirical model (e.g. Extended Kalman filter; horizon approach, self-learning, intelligent (learning) operating system);
- A control toolbox consisting of a Model Predictive Control applicable to a wide range of crystallization processes.

SMART-fm - A Standards-Compliant Framework to Support Complete Integrated Product Life-Cycle Information Management and Electronic Commerce for the Furniture Manufacturing (Fm) Industry, in the Advent of the Smart Enterprises (IMS #01009)

STEP-NC - STEP-Compliant Data Interface for Numeric Controls (IMS #97006)
- Extended an existing data model for turning and milling processes
- A prototype for a turning CNC was developed
- Tested and implemented new measuring equipment

SYMPHONY - A Dynamic Management Methodology with Modular and Integrated Methods and Tools for Knowledge Based, Adaptive SMEs Controls (IMS #00005)
- Created software to help SMEs develop and increase their capabilities to grow
- Developed management methods and tools that facilitate the constant creation, exploration and exploitation of business opportunities within strategic networks
- Symphony product portfolio consist of seven products including SymStrategy, SymResources, and SymCockpit

TES - Recycle system for Composite Material Waste; Thermal Elutriation System (IMS #98032)
- Developed method for recycling materials without dismantling
- Developed a logistics system for collection of disused materials