Industrial Forum IRT 2017 Programme


Day 2, Tuesday, 6. June


8.30 - 9.15

Registration of attendees

 

Hall 1

   
9.15 - 9.45 Intelligent Automation
Jochen Kinauer, Dušan Božič
Inden d.o.o.
Summary
     The ultimate objective of manufacturing lines is to achieve good factory performance and high process quality.Such factory performance is possible only by understanding the relevant processes, monitoring and controlling the process windows, ensuring stable processes, achieving the necessary product quality at all times, guaranteeing error-free production and promptly detecting any anomalies. Collecting and evaluating all of the applicable data and controlling the equipment performance with a high order of complexity are the challenges of automation. The general purpose of automation is to move the right material at the right time to the right place and process it correctly – while controlling all of these steps in real time.The ability to do this reliable, predictable and flexible has a direct impact on factory performance. In this presentation, the main components for automation and quality management will be described and some ROI examples will be given.
9.45 - 10.15 Electric cylinder
Albin Sirc, Jure Peternel
Egasi d.o.o.
Summary
   Development of automation, together with increase of demands for speed and positioning accuracy, offering the opportunity for a new generation of electric cylinders based on tubular direct drive linear motors.The company EGAS d.o.o developing electrical cylinders based on the innovative design of the magnetic circuit, which allows achieving competitive characteristics in the use of significantly smaller amounts of hard magnetic material made from rare earth (NdFeB), which can make the product cheaper and make it even more interesting for potential market. The linear motor consists of a stator part with three-phase winding with integrated position sensor and moving shaft with integrated hard magnetic tube which are multipole magnetised. The electric cylinder can achieve high speed, high acceleration and the possibility for dynamic positioning, which provides a much greater applicability in comparison to the conventional pneumatic positioner. Electric cylinder also can work at high efficiency level , which can result in significant energy savings.
10.15 - 10.45 Design of magnetizing fixtures for magnetizing rotors with the use of programming environment ANSYS Electromagnetics Suite
Ludvik Strauch
Kolektor Group d.o.o.
Summary
     The rapid growth in the development of brushless motors offers various types of rotors. The rotor is basically composed of more permanent magnets. Currently it is technically very interesting rotor which consists of one single piece made in the process of injection molding or pressing. Many motor applications determine the magnetic rotor which is classified by: shape, size, number of poles, types of magnetic materials, and shapes of magnetizations. In the process of magnetization rotor is inserted in the magnetizing fixture where receives magnetic properties. Due to the complexity of the technical characteristics of the rotors we have more types of magnetizing fixtures which are made of coil with or without the soft magnetic core or made of permanent magnets. Because of many problems in the design of magnetizing fixtures it is necessary to use advanced technology with the computer simulations. Therefore, we use in company Kolektor Group programming environment ANSYS Electromagnetics Suite for the design of magnetizing fixtures. According to the technical requirements of the rotor we make the numerical model of the rotor and then the analysis and simulations of electromagnetic parameters. It is necessary to check the various shapes of magnetizing fixtures to reach the magnetic saturation of the rotor. The development of numerical models in the programming environment ANSYS Electromagnetics Suite enables fast, reliable and wider insight into the process of rotor magnetization.
10.45 - 11.15 Developing the hinge for a premium trademark oven – how to fulfil conflicting requirements
Marko Mirnik, Rok Pišek, Aleš Plešnik
Turna d.o.o.
Summary
     As a supplier of parts for kitchen appliances developing a new door hinge for a premium trademark oven, we were faced with technical and technological requirements on one side encompassing the features of appliances for professional use (product life, capacity and loads), and on the other side related to the features of appliances for domestic use (design, ease of use, trends ...). This contribution presents a short summary of our deliberations in the solution-finding process and underlines the significance of good cooperation with the customer in the development phase. By searching for solutions acceptable to both partners, we have developed a product that fulfils all the customer’s requirements for a feasible price.
   
 11.15 - 12.00 Break with exhibition viewing
   
 12.00 - 12.30 A C F - Active Contact Flange
Jože Babič
Halder d.o.o.
Summary
     A C F - Active Contact FlangeRobot handcraft®Our patented technology instantly automates jobs with a high demand for sensitivity and flexibility. It guarantees extremely short cycle times and radical economic ROI, even with delicate applications. The ACF automates problematic handcraft and guarantees high standards of quality. It controls every robot. This even makes retrofitting unbelievably easy and persuasive.Surface treatment:Sand, polish, clean, laminate, strip, brush, remove burrs, iron, laminateAll materials:Steel, aluminium, titanium, magnesium, carbon, plastic, wood, ceramic, coconut fibres, …Contact-sensitive handling:Pick & place, insert, tape, join, pack, assembly, glue, component-testing, quality inspectionPropertys• top quality• simple integration• increases profi tability drastically• tolerance compensation• rapid contacting• short cycle times• closed loop force-control• real-time control• passive safety
 12.30 - 13.00 Robotisation of processes for CNC machine tending
Matej Merkač, Hubert Kosler, Aljoša Zupanc, Damian Širaj, Erih Arko
Yaskawa Slovenija d.o.o.
Yaskawa Ristro d.o.o.
Summary
Robotisation of machine tending significantly relieves the operator and minimizes the impact of human error on the quality of the products. Fully automated process is just one of the important steps that guarantee flawless production of god parts. Accurate machines, repeatable processes with industrial robots and combining multiple processes of manufacturing in one common robot cell are just as important. Advantages of fully automated processes, for achieving of large daily quantities of parts, have been recognized by companies that implemented robots in manufacturing processes, as well as by end customers of products from those companies.
 13.00 - 13.30 The modular assembly cell for Industry 4.0
Zvonko Boštjančič, Matevž Luin, Andrej Šmuc
Blubit d.o.o.
Summary
Based on the modular drive system Beckhoff XTS, we have developed a modular robotic assembly cell for the assembly of fountain pens. A control system based on Beckhoff industrial computer and software TwinCAT coordinates the proper operation of the XTS system, SCARA robot and the individual working units which communicate with the controller over the EtherCAT bus. All operating units are autonomous, quickly interchangeable and automatically recognized immediately when connected to the EtherCAT bus. This allows that the device is used for the assembly of completely different products – only by replacing or adding new working units and by extension of the transport system XTS. In addition the built-in software allows us continuous remote monitoring and analyzation of the production process. With this approach, we follow the development of the industry in the direction of smart factories, also called Industry 4.0. The introduction of modularity ensures a significant increase in utilization of production equipment.
 13.30 - 14.00 Make complexity simple
Igor Lekše1, Janez Sluga1, Domen Rajšelj2
1TPV d.o.o.
2IKU d.o.o.
Summary
     The basic principle of Industry 4.0 is connecting machines, products and people. Smart factory are an autonomous, self-organized, able to make decisions independent and eliminate defects. These are complex systems based on artificial intelligence and stochastic models.Development is more and more intensive and product life cycles are getting shorter. The solutions offer customers better functionalities, automatic and autonomous operation. Equipment is becoming smarter, interconnected and more complex. Nevertheless, we must always and especially today realize that in the practical applications at the end there are following four key user requirements:- Reliability of operation- Efficiency (technical and economic)- Simplicity- ConnectivityFor end users of the solution is most important, that the systems operate reliably, robust, is not sensitive on changes and different external influences. That there are no interventions needed. One of the kay decision factor is efficiency, technical and economical, it means adequately meet the requirements for a competitive price. The third important factor is simplicity of operation and use. The importance of last criteria will even increase in the future.Due to the technological development in all areas, a wide range of solutions and possible applications the selection of correct, optimum solution for specific case is extremely important and mostly difficult decision.In the case of internal logistics automation with AGV we would like to show where and why this solution is optimal in the industry and represents good opportunity for companies to optimize their logistics processes and improve efficiency.
   
 14.00 - 15.30 Lunch and exhibition viewing
   
 15.30 - 16.00 More component shielding gas for welding, aplication and fume generation.
Edvard Bjelajac
Messer Slovenija d.o.o.
Summary
     GMAW welding produce fume gases, which in long term can influence on welder health. Quantity of fume gases are in direct connection with chemical composition of shielding gas.Moderen more component shieldig gases has more goals. Most importent are increase productivity and be more frendly to welder.
 16.00 - 16.30 Adaptive welding of crane parts
Vladimir Magdalenič, Damir Radikovič
VIRS d.o.o.
Summary
     Adaptive robotis welding line is made for MIG/MAG welding of autocrane segments of length 5-15m with implementation of many innovative solutions. The line was manufactured and installed in 2016. The complete welding line was developed in our company.
 16.30 - 17.00 Robotic system for cutting and trimming tubes and profiles (RRC)
Andrej Kreft, Peter Kastelic
Daihen Varstroj
Summary
          DAIHEN VARSTROJ has developed a robotic solution for cutting and trimming tubes and profiles (RRC) which includes a robotic system with the FD-V20A manipulator for cutting and trimming operations of different types of tubes and profiles, with the maximum cutting length of up to 12,000 mm, and maximum cutting length of tubes up to 5,000 mm (up to 1,500 mm without the A3 support lime).
 17.00 - 17.30 Recognition of the forms on the principle of machine learning
Jožica Piškur1, Erih Arko2, Uroš Kromar2, Marko Munih 1
1UL, Fakulteta za elektrotehniko
2Yaskawa Ristro d. o. o.
Summary
     BACKGROUND. The Robotic welding system MOTOSense tracks the butt joints of two metal surfaces and performs an adaptive correction. Very often the metals are previously spot welded which can cause the robot to divert from the desired trajectory. This is the reason for performing an analysis.METHODS. Due to the big number of the existing software packages for image processing, we limited the analysis to the software library OpenCV and the ViDi Suite software, which implements the theory of deep learning. Initially, we manually programmed the spot welds into the ViDi tool welds on test images and later checked them on the other images. While using OpenCV, we tested the algorithm for Template Matching we thus searched for maximum matching of given spot welds.RESULTS. The ViDi Suite proved successfully, although we observed noise on the images. The only limitation of this package is its return of investment. That is why we also tested the OpenCV library, which was in term of recognition not as successful. Most successfully were recognized the spot welds that were taken from the test images.CONSCLUSIONS. For obtaining better results with the OpenCV library we should acquire additional knowledge, such as deep learning, as well as to have more time for testing. In general it was proved that the problem can be solved with ViDi Suite software.KEYWORDS: welding, robot, spot weld, camera, MOTOSense
 

Hall 2

   
 09.15 - 09.45 CNC machine tools accuracy checking and calibration
Luka Čerče, David Muženič, Davorin Kramar, Franci Pušavec
UL, Fakulteta za strojništvo
Summary
     The needs of modern industry to meet narrow tolerances and requirements of international quality standards have led to the fact that the capacity of product machines is more important as ever. Accurate product reflects a geometric accuracy of a CNC machine-tool. In addition to traditional measurements with a measuring gauge, the accuracy test of the CNC machine tool can be performed with a Ballbar test. Additionally, the positional tolerance of the axis movement can be measured with the high accurate laser interferometer. Based on the results, different errors can be eliminated with the correction of parameters in the CNC machine tool controller, and thus improve the positioning accuracy and circularity of CNC machine tool. These parameters have a decisive impact on the surface quality and dimensional accuracy of products. In the paper, an industrial case study of measurement of geometrical accuracy and linear axis positional tolerance compensation of the machine tool is presented.
 09.45 - 10.15 “Why the difference is a matter” and “why Böhler is the right partner”
Johanna Geckle
Böhler Edelstahl GmbH & CoKG
Summary
Whoever claims to be a solid and premium partner in the world of the blanking and forming industry has to set demanding standards. Böhler develops, produces and delivers beside the standard materials advanced cold work tool steels to meet extraordinary customer requirements by considering the creativity of tool making on the one hand and the ever present need of cost-efficiency on the other. In consequence the demands on tool steels are also increasing. The highest performance characteristics demand high strength and ductile tool steels at the same time. An increasing ductility can be reached by improving the homogeneity and the degree of purity. This can successfully be done by means of electro-slag-re-melting (ESR), or by production in a powder metallurgical process (PM). BÖHLER Edelstahl is THE innovative leader in both technologies.If high compressive strength or high ductility is requested ESR or PM produced steels are used for cold working applications. The requirement on such tool steels, like K340 ISODUR and K490 MICROCLEAN, is an optimum of hardness, wear resistance, yield strength, fatigue strength and ductility. During the last years the weight of automobiles increased. Due to increasing weight of vehicles, the trend to develop effective light weight construction strategies is very important.In the scope of lightweight construction new developed high and ultrahigh strength steel sheets offer a great potential regarding mass reduction by simultaneously increasing the safety standards.
 10.15 - 10.45 Hardness Testing of Heat-Treated shafts at Audi Hungary Ltd.
Brigitta Kelenföldi
Grimas Industial Trading Ltd.
Summary
A well known inspection method of heat-treated case depth is hardness testing. Audi Hungary uses nitriding/carburization method to ensure the resistant behaviour of the shafts. Recently destructive testing is the most reliable and precise technology to test nitrided/carburized layers. Audi measures series of hardness indentations to evaluate the depth of the hardened layer and to infer the expected lidetime of camshafts. Audi inspects the shaft in minimum 4 places, at each place they measure 4 series. One measurement series includes a minimum of 4 indentations. So they have to make 64 indentations on one sample. To carry out measurement manually would be very time consuming but thanks to the technology and automatization it is just one click. In my presentation I will show you, why modern hardess testers are really useful for this task.
 10.45 - 11.15 One site. Everything SECO.
Zoran Svenšek
SECO TOOLS SI d.o.o.
Summary
     We've made it easier. To help you navigate complex metalworking processes, we’ve simplified and enhanced your secotools.com experience to provide the resources you need to improve your productivity in one centralized location.
   
 11.15 - 12.00 Break with exhibition viewing
   
 12.00 - 12.30 The revolutionary 3D technology also in Slovenia
Mario Šinko
MARSI, Mario Šinko s.p.
Summary
     Demonstration of 3D laser print (DMLS) of metal products with advanced technology and its benefits.Quality of 3D printed products earlier and today.Fields of application.How to get product in very quick time; description of a case.
 12.30 - 13.00 Punch Tap - Fastest way to make internal thread
Rok Volk
EMUGE-FRANKEN tehnika d.o.o.
Summary
     First three technology for making internal thread are: tap, cold forming tap and thread milling cutter. New 4th technology for making internal thread is Punch Tap, developed by Emuge with cooperation with Audi, to reduce cycle time and increase productivity. In three steps:1.Punch2.thread forming3.RetractionWay to make thread is for 90% shorter in comparison with cold forming thread. Punch Tap can be use only in Aluminium. From this year is also available in other industry, directly to automotive in next year.www.punchtap.com
 13.00 - 13.30 Speedsynchro- 2nd fastest way to make internal thread
Rok Volk
EMUGE-FRANKEN tehnika d.o.o.
Summary
     Speedsynchro is solution for low spindle speed and high tool speed increase for 441%. Programming example:Thread tool M6 with pitch 1mm/Urequierd cutting speed 75 m/min = 4000 U/min for M6programmed spindle speed 4000 U/min / 4,412= 906 U/minprogrammed pitch 1mm/U x 4,412 =4,412 mm/UWith this we save a lot of time, energy and reduced axial forces. Can be use for tap or cold forming tap from M1 –M8
 13.30 - 14.00 Predictive maintenance and Remote Access to machines – as a part of Industry 4.0
Jan Kramžar
Inea RBT d.o.o.
Summary
    Term of Wireless connectivity nowadays presents almost »worn-out« term. In Industry 4.0 Era Wireless connectivity stands as one of prerequisites for Industry 4.0 and allows communication among machines. Wireless technology and remote access technology is known for long time as Wireless Internet is available almost everywhere. Recently concept »Bring your own Device« has appeared, and stands for remote access to machines through Tablet computers and Smartphones. In the same time this concept replaces and exceeds HMI panels. Machine operator is able to remotely set parameters, receive alarms and acquire production quantities. Investing into predictive maintenance is another story which pays out long term. Predictive maintenance means, that operator can help himself by using a device or solution with a bit of intelligence, which to some degree of accuracy knows when some part, lets say bearing, will break and stop working. Mitsubishi Electric for example developed Smart Condition Monitoring KIT which allows to acquire atypical vibrations from drive by using vibration sensor. Datas about vibrations are transfered to PLC controller, from there on to HMI panel or SCADA system – or to Smart Device. Merging »Bring your own Device« and »Predictive Maintenance« concepts means simplifying work of operators and maintainers. Such way of operating and servicing of machines long-termly can offer time and money savings.
   
 14.00 - 15.30 Lunch and exhibition viewing
   
 15.30 - 16.00 Declaration of Conformity
Primož Hafner
LOTRIČ Meroslovje d. o. o.
Summary
Quality assurance is an important factor in all quality systems and calibration is a part of the quality system related to the measurement technique. Calibration means to determine the actual state of the measuring instrument and display to the user how accurate is his measuring instrument. Calibration is actually started when is ordered because it is very important that you as the user of measuring instrument to warn of the calibration operator on any specifics in the application of the criteria in your work process. Specifics are related to the used measuring range of the measuring instrument, to the method of application and to the environmental condition if these are differ from the manufacturer's manuals. Furthermore, the specifics are related to the information listed in the certificate as identification numbers associated with criterion (we can list several: serial, inventory, registration, ward ... number), the calibration procedure, listed the maximum permissible errors (MPE tolerances) listed the declaration of conformity and the listed calibration label. The declaration of conformity or suitability of measuring instrument is the data that the calibration laboratory can listed on the certificate, in order to help the user. In case that the user does not use the standard tolerances must be agreed with the way users because there are several ways of determining the tolerance of which is then dependent on a declaration of conformity. The tolerances may prescribe with regard to legislative frameworks, according to the standard, the recommendations of the manufacturer or according to the requirements of the user itself. This tolerance can be absolute, relative, or a combination of both. The declaration of conformity then tells what the errors are, together with uncertainty in relation to the tolerances. Graphical symbols used by laboratories, enabling a quick overview of suitability by the user, which have saved both the time and the energy when deciding on further use.
 16.00 - 16.30 Using of Numerical simulation and Virtually Reality solution as technical and R&D support for real industrial cases
Marek Slovaček
MECAS ESI s.r.o.
Summary
ESI Group je vodilni inovator na področju programske opreme za Virtual Prototyping. ESI je kot specialist razvil edinstvena orodja za podporo industriji, za nadomeščanje realnih prototipov z virtualnimi prototipi, ki omogočajo da se dejanska proizvodnja, montaža in testiranje predhodno potrdi virtualno. Skupaj z najnovejšimi tehnologijami je Virtual Prototyping ugnezden v širši koncept življenjske dobe proizvoda in obravnava proizvod v njegovem celotnem življenjskem ciklu od začetka do konca uporabe. Oblikovanje hibridnih virtualnih dvojčkov, simulacije, fizika in analiza podatkov proizvajalcem omogoča, da izdela izdelke pametnejše in z več funkcijami. Napovedati je mogoče uporabnost izdelka in predvideti potrebna vzdrževanja. Možnost sodobnih virtualnih rešitev in povezovanje različnih proizvodnih procesov vključno s fizičnim testiranjem se bo demonstriralo med predstavitvijo.
 16.30 - 17.00 The chain of advanced computer optimization procedures for development of new lighter structural elements
Marko Vrh
CADCAM Lab d.o.o.
Summary
     On this present day, the competition on the global market demands lightness, low prices, rigidness, fatigue resistance from the products as well as their timely launch on the market. These requirements are usually contradictory and designers in product development must pursue and fulfill several objectives simultaneously. The easiest way to carry out this process is to divide it into several stages, appoint necessary actions to these stages and then form various solutions. Each of these stages is essentially necessary, but the greatest impact on the further course of the process of introducing a new product have the first stages of the product development such as business analysis, prototype development, validation, commercialization. These are aimed at finding appropriate solutions. Using different types of simulations in these early stages of product development has become a consistent practice in the industry in recent decades, mostly being used for virtual evaluation of different solutions. Especially mechanical calculations of stress-strain responses in various products are in product development practically a necessity as they are repeatedly requested by either contractors or customers. A step forward from the virtual evaluation represent technologies of topological and parametric optimization using computer technologies in product development. These optimizations are not only evaluating exsisting solutions but are also looking for new, better and at this moment still non-existent solutions. These types of technologies are used in our research and development work in CADCAM laboratory. Moreover, they are also being applied in a number of Slovenian companies. In the paper we will show how to use and implement this technologies properly on the example of development of supporting elements.
 17.00 - 17.30 Designing of line for aluminum foil production
Mirko FICKO, Anton JANŽIČ, Ivan PAHOLE, Simon KLANČNIK, Iztok PALČIČ
UM, Fakulteta za strojništvo
Summary
     Floor layout of production system is one of most important factors for success of production system. Good layout of devices ensures short transport times between devices and prevents congestion. This problem is one of the multi-criteria problems where increased number of devices causes combinatorial explosion of possible solutions. This paper presents the design of production line for cutting of aluminum foil. At first the transports frequencies between various devices, space and technical requirements for a line were gathered. For the preparation of the floor space a presentation with triangular mesh was used, and consequently a genetic algorithm for creation of good solution. Prepared layout was in next stage used for creation of actual plan of the production line, which takes into account technological and space requirements. Analysis of the results showed that we acquired near optimal floor layout plan of production line for cutting of aluminum foil very quickly and without need for a detailed analysis of transport.
 

Hall 3

   
 09.15 - 09.45 Development and manufacture of customized cutting tools and coatings for individual tool industry and comparison of the newly developed cutting tools with the cutting tool from renowned competitors
Damir Grguraš1, Davorin Kramar1, David Muženič2, Renato Fijavž3, Igor Guzelj3, Franci Pušavec1
1UL, Fakulteta za strojništvo
2IJS-LJ
3EMO-Celje
Summary
     The Chair of Machining Technology Management of the Faculty of Mechanical Engineering in Ljubljana together with the ''Jožef Stefan'' Institute and the company EMO-Orodjarna developed customized ball end milling tools for machining tool steels in soft state. The workflow of the study was divided into four successive sets of experiments, as follows: 1st set of experiments - analysis of cutting tool material; 2nd set of experiments – effect of cutting edge radius, 3rd set of experiments – effect of rake angle of the cutting tools and 4th set of experiments – effect of different coatings on the cutting tool performance. In all of the listed sets of experiments machinability of the mentioned material was determined by measuring tool life, machined surface roughness and chip shape. The ability of the newly developed cutting tools was also compared with cutting tools from competing renowned manufacturers. This paper includes a presentation of the results obtained in the individual sets of experiments or the final determination of the most favourable cutting tool in terms of the cutting tool material, the radius of the cutting edge, the rake angle and the coating in machining the mentioned steel. The comparison of tool life between the newly developed cutting tool and the cutting tools from competing renewed manufacturers is also presented.
 09.45 - 10.15 Structural dynamics analysis using high-speed camera
Janko Slavič, Jaka Javh, Domen Gorjup, Miha Boltežar
UL, fakulteta za strojništvo
Summary
     In recent years we have seen a significant improvement in the performance of high-speed cameras. The article shows how the fastest camera in the world (up to 2.1 million images per second) can be used for the analysis of structural dynamics. Besides the technological progress we have seen also a big progress in the field of image signal processing; the frequently used digital image correlation is only one of the approaches possible. Here a method based on the gradient intensity of the image with be discussed which can identify the modal shapes on the level of 1/10000th of a pixel. Some real applications from industry will also be presented.
 10.15 - 10.45 Importance of determining sheet material properties in toolmaking
Mihael Volk
Gorenje Orodjarna, d.o.o.
Summary
     The sheet metal forming processes are becoming increasingly complex and demanding. The tooling must be designed so that we can benefit from all the sheet metal forming potentials as well as possible. Product quality varies between sheet manufacturers and the tolerances for the material properties are relatively wide. Interestingly, despite having the same designation and falling inside the same standard tolerances, two materials can exhibit quite different forming properties. Testing materials to optimise the tooling and manufacturing processes is therefore highly recommended and necessary to determine the material properties. These are key for troubleshooting when commissioning new tools. Furthermore, new materials with not yet known material properties are coming to the market, and this is where Gorenje Orodjarna sees many opportunities. Determining the material properties of sheet metal is therefore highly significant and for this purpose we have developed a new way for material characterisation by determining the forming limit curves.
 10.45 - 11.15 Solving of complex problems in small and medium enterprises
Josip Kos, Tomislav Hercigonja, Nenad Drvar
Topomatika d.o.o.
Summary
     Reducing the time from development to the finished product which is ready for sale is a key requirement for manufacturers and suppliers in the automotive industry. One way to achieve a reduction in the time of the production cycle is to improve the quality control in production. For this purpose more and more companies use automated measuring cells for rapid measurement of tools and components at all stages of the production process, which in addition to shortening the measurement time effectively reduces the human error. Paper presents an overview of successful industrial applications using ATOS ScanBox automated measuring cell on specific examples from the fields of tool making, foundry and sheet metal forming. In the course of the presentation, we will demonstrate remote programming. In Portorož we will carry out the automatic planning of 3D scanning which will be launched at ATOS ScanBox 5120 in Zagreb via the Internet and video-link.
   
 11.15 - 12.00 Break with exhibition viewing
   
 12.00 - 12.30 With online measurements based on 3D scanning to inline inspection of maintenance procedures
Samo Gazvoda, Luka Botolin, Matej Vurcer
TECOS Razvojni center orodjarstva Slovenije
Summary
3D scanning, while being a well established process in nowadays industrial practise, is still often considered as not being precise enough. The paper presents case studies which illustrate how it is possible to drastically speed up the most demanding procedures of maintenance, repair or restoration of old tools, machines and devices which do not have appropriate 2D or 3D documentation. In the introduction it also reflects on accuracies achievable with 3D scanning.
 12.30 - 13.00 Modular displacement sensor for precise 3D measurements and failure detection
Rok Mihelj, Peter Lepej
VISTION d.o.o.
Summary
Nowadays machine vision plays important role in production processes, especially for quality control of finished products. 3D sensors are more and more popular and capable of precise measurement in 3D environment. Laser is one of the main parts of V25D sensor. It projects laser line in front of the camera and adds one more dimension of element. This procedure is simple and very popular to get information about scanned object and it is proven as very effective. To get best results in implementation of machine vision in different production processes modular approach of building a system should be used. With presentation new innovative way about how to construct 3D sensor, which is modular adaptable for different requirements of the customer, will be presented.
 13.00 - 13.30 Transfer to the production floor and automation of a high speed comparative gauge for inspection of medium to high volume manufactured parts
Simon Smolnikar, Žiga Rupret
RLS Merilna tehnika d. o. o.
Summary
In the modern production world, increased emphasis is given to multifaceted optimisation within individual production cells that make up the overall production process. Based on years of experience and connections with partners from different manufacturing companies and sectors Renishaw has developed technology that allows companies to optimise and monitor their production process in one place.In middle and high volume production where it is necessary to regularly control the workpieces, time in manufacturing is very important. Therefore, it is essential for the companies to dedicate time in optimisation.To automate the production process, measurement technology has been developed that enables connectivity and communication between robots and machine tools. This complete automated unit can provide smooth, autonomous processing of the workpiece, robotic manipulation, final inspection and feedback to machine tool if any necessary corrections of the machine are needed in order to achieve the set workpiece tolerances.Development in automated production measurement has followed the industry 4.0 scenario, where rutine processes are fully automated, managing the quality for the purpose of cost reduction and time optimisation.In our paper we would like introduce the concept and technology of production automation and measurement o the public, based on good practices from the global market.
 13.30 - 14.00 Toolmaker and plastic processor – partners or competitors
Aleš Adamlje
HELLA Saturnus Slovenija d.o.o.
Summary
The increasing complexity of products and moulds requires the toolmaker and plastics processor to work together in all development phases of the product and the mould. The concept of product and mould has a key impact on the productivity and maintenance costs of moulds during the entire product life cycle. The expected results can be only achieved by applying modern engineering methods and principles of concurrent engineering. The aim of the processor of plastics - polymer materials is to manufacture a high-quality product in the planned cycle time at the lowest possible cost. To achieve high productivity, the requirements for product and mould must be defined precisely. The requirements for the mould provided by the plastics processor enable the toolmaker to assess its ability to manufacture the mould, prepare a technically appropriate offer and, if they get the contract, to manufacture a mould that will enable the plastics processor to produce competitively throughout the entire product lifecycle. The mould requirements must include information on the desired mould concept, materials of mould plates and standard parts of moulds, and the runner, tempering and ejecting systems. Before relaying product 3D data to the toolmaker, the plastics processor must analyse the feasibility of the product (DFMA). In the offer and mould concept preparation phase, the toolmaker will repeat the product feasibility assessment. In order to achieve high levels of productivity in the product manufacturing process, mutual cooperation between the toolmaker and the plastic processor is crucial. Their common target orientation contributes to an increased competitiveness in the manufacturing process of them both.
   
 14.00 - 15.30 Lunch and exhibition viewing
   
 15.30 - 16.00 Influence of cold weld on the mechanical properties of polymeric materials
Anton Kočar, Andrej Glojek
TECOS, Razvojni center orodjarstva Slovenije
Summary
     Polymeric materials nowadays are widespread and practically used in all the industry branches. As they excel in relatively affordable price, the materials also incorporate a broad spectrum of different mechanical properties. Geometry of the product and fabrication technology during the injection moulding can cause cold welds on the specific plastic components. Those indicate visual defect and mechanical weakness on the moulded components.The objective of the research work is to research the cold welds’ influence on the mechanical properties of three different polymeric materials. The research embodies detailed description of the standardly moulded tensile specimens with and without a weld lines. Mechanical properties of the specimens have been tested on tensile testing machine.As the result of the testing there were provided engineering stress strain curves. Based on the results of the experimental testing there was determined the cold welds' influence on the mechanical properties. Also in the research, there are presented the methods of the cold welds' modelling with computational numerical simulations. In the research there was used the mapping method, where material data was mapped from the finite elements' mesh based on injection moulding simulation to the finite elements' mesh based on the structural simulation. The computational numerical simulations' results were compared and evaluated with the results of experimental testing.The results of the research work offer important conclusions on the field of injection moulding of polymeric materials, since we were provided with significant experience considering cold weld strength prediction
 16.00 - 16.30 Polymerization of epoxy binders for bonding the electro-plates in the laminated cores
Ines Bergoč1, Urška Žonta2, Špela Bolka3
1SiEVA d.o.o.
2Hidria Rotomatika d.o.o.
3Nela d.o.o.
Summary
     The automotive industry is following the trend of hybridization and electrification of power trains. Thin steel sheets which are used for the manufacture of laminated segments and cores of the electric motors are those of higher quality. Due to their thinness, conventional technologies of joining them into final laminated segments or cores are not an option. Production of the active components of electric motors consists of thin-film coatings on thin electrical steel sheets which in addition to providing insulation serve also as a binder. Semi-hardened insulation coating is composed of an epoxy polymer. The hardening process is done at a high temperature for a certain amount of time. The optimum time and temperature may be evaluated by monitoring heat or energy, which is released during the hardening reaction. Differential scanning calorimetry (DSC) is a measurement technique that enables the measurement of the exothermic response of coating polymerization at a given temperature or time. For optimal coating hardening the optimal heating rate of the insulation is to be defined in addition to the time and temperature. Too high heating rate can result in the shift of hardening reaction to higher temperatures which can lead to partial thermal decomposition of the coating, thus worsening the final properties. Low heating rate can lead to hardening at low temperatures which is not intense and longer times and temperatures ranges are required for a complete reaction. The paper includes studies of the impact of heating rate and temperature range of isothermal exposure on polymerization process of the coating to provide optimal parameters in the technological process of joining thin electrical steel sheets into final laminated segments.
 16.30 - 17.00 Developing a polyurethane casting technology adapted for modular construction
David Močnik, Uroš Zaletel, Matej Možina, Andrej Šuštar, Katja Udovič, Gabi Globokar, Nataša Kurent
REM d.o.o.
Summary
     Increasing demands for energy efficiency, better material utilization, higher quality and lower costs have led to the development of new materials and technologies for thermal insulation. As opposed to the polyurethane foam casting technology mostly used by our competition in addition to the installation of prefabricated polyurethane plates, REM d.o.o. has decided to develop a polyurethane casting technology adapted to the needs of modular construction. This technology is a novelty in modular construction of units in Slovenia and wider. Since there is no waste, we have managed to achieve an ideal utilization of input material, while the operation’s technological time was reduced by 50 % in comparison to the moulding technology. Together with experts from Polychem Systems we have conducted numerous tests and determined an optimal chemical composition of polyol and isocyanate components, optimal temperature of both components, ambient temperature and the required mould temperature. This guarantees process repeatability, optimal density of polyurethane foam and minimum thermal conductivity. The tests of new polyurethane foam’s thermal conductivity at the Slovenian national building and civil engineering institute (ZAG) have shown that an improper selection of these influential parameters is very detrimental to the quality of polyurethane foam, with variations in excess of 30 %. The implementation of this innovation has made it possible to launch the product on new global markets, while strengthening the company’s position and improving the market share on the existing markets.
17.00 - 17.30 Optimization of properties of polyphenylene sulfide (PPS) injection molded parts by factorial design of experiments
Janez Slapnik, Rajko Bobovnik, Silvester Bolka, Thomas Wilhelm
Fakulteta za tehnologijo polimerov
Summary
     This paper presents an optimization procedure for mechanical, thermal and optical properties as well as dimensional stability of PPS injection molded parts via software supported factorial design of experiments. Melt temperature, mold temperature, injection velocity, drying temperature and drying time were chosen as variable process parameters. Mechanical and thermal properties were characterized by tensile testing, Charpy impact testing, dynamic scanning calorimetry (DSC) and dynamic mechanical analysis (DMA). Optical properties were characterized by surface quality evaluation. Dimensional stability was estimated by shrinkage measurements. Response optimization was performed, which proved that factorial design of experiments is an effective method for optimization of PPS injection molded parts.
 

Hall 4

   
 09.15 - 09.45 Training and occupational standard in the field of composite manufacturing - CompoHUB project
Gregor Cerinšek
UL, Inovacijsko-razvojni inštitut
Summary
     Traditional industrial sectors are labour intensive and characterized by high levels of manual work. In the past years, the production was globally moving to the areas with cheap labour force, causing high levels of long-term unemployment in the respective sectors such as wooden and textile industries. However, opportunities reside in the composite industry, which is characterised by high added value and high complexity of manual work processes. The shortage of skilled labour in the composite industry results from its specific complexity, requiring working habits, working experiences and manual skills – all these tacit assets can be offered by the surplus and currently unemployed labour force from the traditional industrial sectors. CompoHUB project will use the current potentials offered by the labour market as a baseline and furthermore involve additional training activities to re-qualify the surplus labour force to be able to work effectively in the high-tech area of composite industry. The key aim of the CompoHUB project is to develop a holistic training programme to educate, train and – consequently – properly qualify the workers in the field of composite manufacturing, i.e. composite laminators, which will be responsive to the real identified market needs and tailored to the specific identified requirements of the target training group. In addition, the project is developing the occupational standard, which describes relevant knowledge, skills and typical working tasks in the field of composite manufacturing.
 09.45 - 10.15 Basics of composite structures
Sašo Knez, Jure Pocrnjič, Nino Razpotnik
Aereform d.o.o.
Summary
This lecture is meant for all the designers and engineers that have not yet encountered composite structures in their work process. We will answer the basic questions about what is a composite and what are the most common constituent materials in composites.We will lightly touch mechanical properties of composites. But the core of the lecture will be the practical use of composites. What are structures that are most favourable for composite use? What are the rules and guidelines when constructing composite structures? What are core constructions? How do composites cut and how to bond them?The lecture will be supported by practical examples both of positive and negative nature. We will also have samples and physical parts to further show what will be given in the lecture.
 10.15 - 10.45 Influence of fabrication technology on mechanical properties of carbon-epoxy composites
Zoran Bergant1, Adriana Savin2, Janez Grum1
1UL, Fakulteta za strojništvo
2Nondestructive Testing Department, Mational Institute of R&D for Technical Physics, Iasi, Romunija
Summary
     Manufacturing technology influence the mechanical propertie s of composites because of difference in ratios between fibers and matrix obtained. The statical tensile, compressive and bending properties of 8-ply quasi-isotropic and orthotropic laminates were investigated. Furthermore, dynamical mechanical analysis was performed on laminates between 30-250 ?C at frequencies between 1-50 Hz. The laminates were produced using autoclave-prepreg processing method and wet lay-up with vacuum bagging. The magnitude of improvement of statical properties of autoclave prepreg processed laminate was between 24-42 %. In mechanical dynamical analysis, the damping of autoclave prepreg processed laminate was by 1.8-times lower than in wet-layup specimens. Furthermore, slighlty lower Charpy impact toughness was found in autoclave-prepreg processed specimens.
 10.45 - 11.15 Composites and industrial production - the use of composites in the manufacturing of exhaust systems
Dejan Kastelic
Akrapovič d.d.
Summary
At Akrapovič we use high-performance composite materials in the form of glass, aramid, and carbon fiber–reinforced resin in which the resin system consists of various types of epoxy and other high temperature resins. All of these are top-of-the-line materials that are used in other automotive and aerospace industries.The unique challenges for composite materials in our company are attractive design, where the material also needs to withstand high temperature loads in addition to being lightweight and durable. The biggest challenge is to find high-temperature resin systems that have aesthetic properties acceptable to us.We mainly use two general manufacturing processes. Hot press moulding and prepreg/autoclave. Product development, tool design, tool manufacturing and part manufacturing are all done in house due to high quality requirements.
   
 11.15 - 12.00 Break with exhibition viewing
   
 12.00 - 12.30 Manufacturing and certification of composite pressure vessels according to ASME Section X
Ted Prodan
MARE d.o.o.
Summary
Although the most widely used construction code for composite pressure vessels is the ASME Boiler and Pressure Vessel Code Section X, this standard is so technically demanding that worldwide only 21 manufacturers fulfill its requirements. Furthermore, among these only 4 manufacturers fulfill the technical requirements applicable to manufacturing Class I and Class II vessels - our company is one of these 4.This paper introduces the construction code and the differences between the aforementioned pressure vessel classes. It then presents the various engineering and technical challenges that a composite manufacturer faces during the product development phases of design, production, testing and certification.Proper emphasis is put on the anisotropic nature of composite materials, and how this complicates the design calculations, testing and evaluation of results. Presented are analysis methods, and how these need to be verified and validated before they can be considered acceptable by the construction code.These analysis methods and procedures are not only applicable to composite pressure vessels, but hold true for many different fiber-reinforced composite products. Therefore, the paper presents knowledge that is interesting to a larger number of composite manufacturers.
 12.30 - 13.00 Production of one of the largest housings for wind power plant
Polona Zrimec, Igor Zupan
ELAN d.o.o.
Summary
In 2015, Elan began the production of a composite housing for one of the largest serial wind power plant in the world. The entire housing consists of "smaller" individual pieces, which are then put together into a whole. The assembled set is 12 m long and has a diameter of more than 6 m. The production of individual pieces uses CNC-prefabricated fibers and a 100% vacuum infusion. At the moment, the pieces are still processed manually (pruning, drilling, etc.), but for the future an automation project using robots has been prepared too.
 13.00 - 13.30 Composite materials as competitive advantage – example of composite materials implementation in ultralight plane construction
Bogdan Skaza
Pipistrel d.o.o.
Summary
They understand competitive advantage as being buyers first choice in comparison to other manufacturers. Products of company Pipistrel d.o.o. Ajdovščina are present on the market now for over 25 years. Pipistrel planes are made of more than 5000 different parts made by 400 business associates around the globe. In this moment, there is 95 people employed, 35 of them are developers. In this segment, of research and development of ultralight planes, this is the leading company. Their superiority is mainly in innovative engineering and perfection regarding product development. As airplane manufacturers, they cannot separate design and functionality of the products, but they have to combine those two, as shape of the planes defines their performance and functionality. To get best possible result and technological solutions modern materials should be used, one segment of them present composite materials. As they say, they cannot imagine ultralight plane without composite materials implemented in them, as they offer great corrosion and chemical resistance, are easily formed in complex shapes, are really light, yet strong enough to take harsh loads. Because of these positive characteristics composite materials are used for making many different plane parts. Different point of views on implementing composite materials in ultralight plane construction will be shown, mainly their experience as result of their development.
 13.30 - 14.00 ThermoComp – revolutionary processing technology using thermoplastic composites for lightweight structural products
Boštjan Žagar
Center za aplikativne polimere d.o.o.
Summary
     ThermoComp introduces advanced termoplastic composites, also referred as “material of the future for mass production” into fully structural (and aesthetical) lightweight products. By utilizing in-house developed revolutionary heat manipulation system which enables ThermoComp to process parts at unseen speed (5-8 times faster comparing to existing (thermoset based) technologies, 50% production price savings), at the same time eliminating environment impacts (ZERO VOC emission) and introducing unique hybrid nature of the technology (able to process existing thermoset composites and advanced TPC materials). Such approach is significantly decreasing investment costs and as being scalable (semi or fully automated) is a game changer in the industry and attractive option for SMEs in even wider composite processing sector.
   
 14.00 - 15.30 Lunch and exhibition viewing
   
 15.30 - 16.00 Hybrid fibres in composite products
Ana Pilipović, Petar Ilinčić
Faculty of Mechanical Engineering and Naval Architecture
Summary
    Numerous excellent properties of composites materials, low costs and simplicity of production have resulted in large expansion of their application area. Composite materials/products have to be of low weight, high strength, rigidity and high impact strength regarding density, as well as of excellent physical properties. Because of the main characteristics of composites products (they are combined from two or more materials of different properties, producing a product with the properties different from any of the individual components), all properties can be achived by application of hybrid fibres, mixing different fibers or different orientation of fibres. The paper presents the procedures laminated hybrid composite plates composed of carbon and glass fibres and the testing of their mechanical properties. In the former case, the central layer of the composite plate is made of glass fibres and the external layers are made of carbon fibres, but in the latter case, the central layer is made of carbon, and the external layers of glass fibres. For the third plate it was used carbon and aramid fibres in a different layers and angles and tested mechanical properties. From tests it can be concluded that different lay-up of such hybrid fibers contributing to certain properties, and it was desirable to apply the glass fibres due to their cost, combined with the more expensive carbon or aramid.
 16.00 - 16.30 Problem-based and experiential learning in the area of composite manufacturing - case of Eltrak
Iztok Kordiš
Waldorfska šola Ljubljana
Summary
Problemsko-naravnano in izkustveno učenje v središče pedagoškega procesa postavi učenca, ki pridobiva znanje o določenem pojavu ali tematiki na podlagi reševanja konkretnih problemov in izzivov. Učenec si na ta način pridobi dragocene izkušnje ter poleg znanja razvija svoje sposobnosti ter kompetence. Eltrak je primer tovrstnega učenja in projekt Waldorfske šole Ljubljana, s katerim želimo krepiti področje tehnike in razvoj tehnične kulture na gimnaziji v okviru projektnega dela, povezovanja dijakov in študentov. Vključevanje več partnerjev (FS UL, RLS, Aereform, učitelji, starši) v projekt omogoča gimnazijcem seznanitev in vzpostavitev povezave z uspešnimi slovenskimi podjetniki in univerzitetnimi pedagogi. Pri projektu je pomembno tudi ozaveščanje okolju prijazne uporabe novih tehnologij in materialov. Razvija in spodbuja se kreativnost in inovativnost mladih ter sposobnost realizacije idej na tehničnem področju. Eltrak je električno napajan, daljinsko voden ratrak, prvenstveno namenjen za pripravo tekaških smučin tako za klasično kot drsalno tehniko. Z modularno zgradbo in možnostjo različnih priključkov pa je uporaben tudi za druga dela in prevoze v naravnem okolju tako pozimi kot poleti. Projekt je kompleksen – poleg električnega in strojnega dela zajema tudi izdelavo kabine, ki je izdelana iz kompozitnih materialov.
 16.30 - 17.00 Identifying the defects causes in the plastic products through the analysis of the material or products
Silvester Bolka, Janez Slapnik, Rajko Bobovnik
Fakulteta za tehnologijo polimerov
Summary
     To ensure constant quality in the manufacturing process of plastics, the processing parameters need to be adjusted according to batch-dependent variations of raw material properties. To ensure constant product properties, a lot of experience is needed and the right equipment needs to be chosen for the analysis of the manufactured parts to detect the causes for problems. At the Faculty of polymer technology, we help the plastics industry in identifying these causes.. The use of recycled materials is becoming more and more important, both recyclate from production as recycled material purchased on the market.. When making a decision not only the price is important, but also the required characteristics of the finished product. In this article, we will present examples using recycled polyamide, recycled polycarbonate and will point out possibilities of “up-cycling”. In the case of recyclate, it is important to analyze the thermal and mechanical properties and determine an acceptable composition. At “up-cycling” of market available recyclate, it is important to ensure good compatibilization to enhance the processability. Regarding the processing of composites with glass fibers, it is important to be aware of the fact that the stiffness and strength drastically decrease with each processing cycle. All presented analyzes were performed on our own equipment in the laboratory of the Faculty of polymer technology.
 16.30 - 17.00 Measurement of chamber furnace tecnological parameters for rolls heat treatment
Blaž Karpe1, Sergej Novak1, Simon Rečnik1, Borislav Košec2, Aleš Nagode1, Borut Kosec1
1UL, Naravoslovnotehniška fakulteta
2Valji d.o.o.
Summary
     Within the sphere of work experimental activities, technical measurements of gas fired chamber furnace Bosio PP CP-70/1150, through the entire heat treatment process of HCS rolls was carried out. Measurements were performed in an industrial environment in the company Valji d.o.o. The main purpose of the work was to assess the operation of the gas fired chamber furnace Bosio PP-CP 70/1150 and its impact on the performance of demanding heat treatment. Temperature measurements were taken during heat treatment process with additional thermocouples in different areas on the surface of the rollers, and at the same time temperatures were monitored in all heating zones of the furnace. With finite difference method and computer simulation we calculated temperature profile across the roll cross section. As regards the assessment of the furnace efficiency, temperature of all external walls of the furnace were measured. As part of the experimental activities were also carried out measurements of CO and NOx emissions to evaluate ecological integrity.
   
 17.30 - 19.00

Draw of prizes in Hall 1

   

 

Partners from Industry


ACRONI, d. o. o., AKRAPOVIČ, d. d., BSH Hišni aparati, d. o. o., Cimos, d. d., Danfoss Trata, d. o. o., Domel, d. d., Hella Saturnus Slovenija, d. o. o., Hidria, d. d., Gorenje Orodjarna, d. o. o., Iskra Mehanizmi, d. d., Isokon, d. o. o., ITW Metalflex, d. o. o., Kolektor Group, d. o. o., Kovinoplastika Lož, d. d., LAMA Avtomatizacija, d. o. o., LITOSTROJ POWER, d. o. o., SIBO G, d. o. o., TPV, d. d., Trimo, d. d., TURNA, d. o. o., Unior, d. d.

Main Sponsor:

 

National Sponsor:

 

Sponsors:

 
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Sponsors of the composites section

 

Organizer:


PROFIDTP, d. o. o.

Gradišče VI  4,
1291 Škofljica,
Slovenia
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