Robotanvendelser i olje og gassindustrien

Transcription

1 1 Robotanvendelser i olje og gassindustrien Olav Egeland Professor ved Institutt for produksjons- og kvalitetsteknikk, NTNU Forum for automatisk produksjon, Ålesund, august Department of Production and Quality Engineering, NTNU Groups 1. Production Systems 2. Production Management 3. Project and Quality Management 4. Reliability, Availability, Maintainability and Safety (RAMS). NTNU Revolve: Formula Student Race Car 1

2 3 Production Systems Group Department of Production and Quality Engineering, NTNU Activities: Robotic Automation Manufacturing Processes Drilling Automation Subsea Control Systems Facilities: Robot Lab Manufacturing Workshop Subsea Control Lab 4 Department Lab and Workshop Additive Manufacturing Concept Laser M2 3d-printer for metal (2010) Metrology Leitz Coordinate Measuring Machine PMM-C 600 Electrical Discharge Machining Makino U53K Wire EDM (2000) Agie Die-Sinking EDM (1997) CNC OKUMA GENOS L200 E-M Multi- Function Lathe (2012) Robotics 2 Nachi Robots 4 Universal Robots 2

3 5 New Sustainable Production Lab at NTNU New Robot Cell for Welding and Assembly 2 Large Robots, 2 Welding Robots Stereo Vision, Force Control Off-line Programming New Robotic Cell for Sensory Control 2 Small Robots Stereo Vision, Force Control Optical and Tactile Metrology Off-line Programming Main Target Sustainable Production for the Maritime and Offshore Industries using Robot Solutions Research Topics Off-line Programming Automatic Calibration and Metrology Stereo Vision, Sensors and Force Control Robotic Welding 6 University Research: Best Practice Research Group 1. Headed by one professor 2. Coordinated research by 5-10 PhD-students and 1-2 Post Docs 3. Research Lab 4. Funding from EU, research council and industry (10 mill NOK per year) 5. Publications in scientific journals and at international conferences 6. Teaching of 2-3 courses 7. Graduation of about 10 master students in coordination with PhD research 8. Accumulation of knowledge: Theory, methods, SW, HW, lab setups Coordinated Research Groups 1. Organized for running major research programs 3

4 7 Research Strategy at a Technical University International Trends The research strategy should be developed in agreement with international trends to take advantage from international research development Own Strengths The research should be based on the competence of the group so that the group can reach a world class level Economic Engine To secure long-term funding, the research should be of vital interest to technology-driven industry sectors that are nationally significant 8 Marin kybernetikk Strategisk universitetsprogram Deltagere: Institutt for teknisk kybernetikk og Institutt for marin teknologi, NTNU 2. Finansiering av 10 PhD-studenter 3. Budsjett: 12 millioner 4. Prosjektleder: Professor Olav Egeland Resultater artikler, 53 papers og 6 internasjonale bøker PhD hvorav 2 er professorer på NTNU 3. Ett oppstartselskap: Marine Cybernetics AS 4. Forløper til SFFene CESOS og AMOS 4

5 9 10 Norwegian Industry structure Offshore and subsea industry Large national industry with high profitability and world leading products Engineer to order Production in Norway Maritime industry Highly international industry where advanced products are produced in Norway Specialized manufacturing Small batch production of specialized products High value added Manufacturing Production in Norway Furniture, electrical heating, automotive,... Larger batches 5

6 11 Offshore and Subsea Industry National Advantages Specialized competence developed over many years Broad range of specialized products Clustering Effects Implications Barriers for foreign competitors Potential for increased efficiency 12 Production Automation: Economic Engine Manufacturing The European Union promotes manufacturing research in Europe based on a long-term shift from cost-based focus to competition based on products of high added value, small batch sizes, changeable production requirements and complex tasks. Drive for automation in Norwegian manufacturing with support from the research council. Offshore and maritime industries Robotic Automation of small batch, high value added products. Drilling automation and subsea operations are closely linked to robotics. Major research initiatives with funding from industry and research council Great potential for synergy 6

7 13 NTNU Research Strategy on Production Systems Develop technology for sustainable production in Norway Case studies on small batch production in manufacturing and in the offshore and maritime industries Establish a technological infrastructure based on case studies Use this infrastructure to speed up progress in R&D Exploit synergy between manufacturing industry, and the offshore and maritime industries. Case studies Robotic Automation of manufacturing processes based on vision and force control Robotic welding applications Production of ship equipment Drilling Automation Subsea robotics 14 NTNU Research Strategy on Robotic Production Main idea: Develop robot solutions for implementation of advanced industrial applications Approach: Use the original robot control system Add sensors like camera systems, laser sensors and force sensors and control systems for sensorbased corrections to robot control system Important issues: Rapid set-up and implementation of robot solutions Efficient switching between different products Offline programming and calibration 7

8 15 Important Parameters for Profitable Robot Automation Small-batch production Installation and set-up of robot cell Integration of sensors, SW and HW Robot programming Change from one product to another, parameterization of product families Mass production Cycle time Nonproductive time 16 Offshore Mechatronics Research Initiative of UiA and NODE Partners: NTNU, University of Texas at Austin Research Topics: 1. Top-Side Drilling Automation 2. Condition-based monitoring of drives and actuators 8

9 17 Offshore Mechatronics: Top-side Drilling Automation Target: Automatic Drilling Technology Control Systems Modeling and Simulation Fault detection and handling Robotics Computer Vision Detailed studies on Motion Compensation Electric and Hydraulic Actuators Friction issues Vibration damping Simulation tools 18 Drilling Automation Absence of Operator: Implications Need for additional sensors Need for automatic detection of situation Need for automatic handling of situations System reliability of increased importance Additional Sensors Vision systems, including stereo, motion detection, point clouds and laser distance sensors Sensors for detection of faults: Accelerometers, load cells, pressure measurements. Use of existing sensors for fault detection. Wireless sensor arrangements can be useful Detection of situation Formalization of different situations (discrete states) Develop criteria for identification of discrete states Use of particle filters, fault detection schemes Handling of situation Formalization of procedures and techniques for automatic handling of all possible situations 9

10 19 Offshore Mechatronics: Condition-based monitoring Target: Detection of potential faults to avoid down-time Advanced sensors, detailed physical models, and insight to make reliable predictions and avoid false alarms Technology Condition-based maintenance On-site condition monitoring Sensor systems and computer vision Combining control and condition monitoring Detailed studies on Corrosion and wear on drives and actuators Wear on wires and fiber-rope in heave compensation 20 EFFEKT: Effektiv Produksjon av Avansert Skipsutstyr Brukerstyrt prosjekt Deltagere: Brunvoll, Oshaug Metall, SINTEF, NTNU og Møreforskning % finansiering med 10 millioner fra Forskningsrådet over MAROFF Problemstilling 1. Bedriftene skal produsere i Norge 2. Produksjon av små serier, produkter med høy verdiskapning 3. Stor grad av manuell produksjon Målsetning 1. Utvikle strategi og lean logistikk 2. Robotisert automatisering av produksjon av små serier 10

11 Zero defect manufacturing Intelligent Fault Correction and self Optimizing Manufacturing systems FoF NMP The participants: 11

12 IFaCOM Concept and Framework Main idea Introduce feedback from additional sensors for correction in the production phase to achieve zero-defect production The three feedback loops The real time vital parameter control loop. The process optimization loop (medium term optimization). The machine system optimization loop (long term optimization). 24 IFaCOM: Intelligent Fault Correction and self Optimizing Manufacturing systems EU-prosjekt FP7 1. Norske deltagere: NTNU og GKN Aerospace 2. Koordinator: IPK, NTNU 3. Budsjett: 10 millioner euro 4. Del av NMP, Factory of the Future med fokus mot implementering i SMBer. Målsetning 1. GKN demo i samarbeid med NTNU: Robotisert sveising av inconel 718 for produksjon av bakre ramme av jetmotor for passasjerfly. 2. I tillegg 4 andre demoer innen produksjonteknologi og aerospace. 3. Feilfri produksjon (Zero-Defect Manufacturing). 12

13 25 Robotic welding of jet engine rear-frame IFaCOM demonstrator at NTNU PhD project with GKN Robotic alignment of turbine panels for tack welding Stereo vision, laser triangularization and force control Control of TIG welding parameters 13