This paper discusses the development of EDAP 4.0, which stands for "Engine Digitalized Assembly Plant," a digitalized endothermic engine assembly station. The project was born through the collaboration between RME (Robby moto engineering), MADE, and the Politecnico di Milano above the necessity to innovate the way piston aero engines for ultralight aircraft are assembled. Nowadays, aircraft engines in this sector are assembled manually because the production volumes are very small in comparison with, for example, the automotive sector. Indicatively the most important companies have production between 20 and 90 units per day while for smaller realities productions are about hundreds of engines produced in the whole year. For example, in the automotive sector, FIAT alone produces about 2,000 engines per day. In addition, the reference regulations, DOA and POA, are very stringent. Indeed, they require very detailed procedures and documentation, from the definition of the company's organizational chart to the necessary controls over the operations carried out during production. All these factors result in a high expense of resources and low efficiency of the whole system. The development of a new methodology, taking advantage of 4.0 technologies, is of interest, and this paper, it will be shown how the station was developed both at the mechanical level and the logics chosen at the software level. The station consists of a workbench, a dedicated IT infrastructure, and mechanical support that allows the operator to be able to efficiently and ergonomically assemble the motor. At the software level, the station will be equipped with a dedicated version of a company MES that will allow real-time communication with the company's production, warehouse, and sales. The software will then make available a guided and controlled procedure to the operator, which will support him from the first stage of picking components from the warehouse to the end of assembly. In order to verify the steps taken by the operator, all the tools required to assemble the engine will be digitized and connected to the EDAP software. All the data generated will then be used to perform analysis on assembly performance, timing, and efficiency.
Questo lavoro tratta lo sviluppo di EDAP 4.0 acronimo di "Engine Digitalized Assembly Plant", una stazione digitalizzata di assemblaggio di motori endotermici. Il progetto è nato grazie alla collaborazione tra RME (Robby moto engineering), il MADE e il Politecnico di Milano sopra la necessità di innovare il modo in cui vengono assemblati i motori aeronautici a pistoni per velivoli ultralaggeri. Al giorno d'oggi, i motori aeronautici di questo settore vengono assemblati manualmente perchè i volumi di produzione sono molto piccoli in confronto ad esempio con il settore automotive. Indicativamente per le aziende più importati si parla di produzioni tra le 20 e le 90 unità al giorno mentre per realtà più piccole si arriva anche a parlare di centinaia di motori prodotti nell'intero anno. In confronto nel settore automotive, per esempio, solo la FIAT produce al giorno circa 2000 motori. In aggiunta le norme di riferimento, DOA e POA, sono molto stringenti. Esse infatti richiedono procedure e documentazione molto dettagliata, dalla definizione dell'organigramma dell'impresa ai controlli necessari sulle operazioni effettuate durante la produzione. Tutti questi fattori risultano in un dispendio di risorse elevato ed efficienza di tutto il sistema bassa. Lo sviluppo di una nuova metodologia, che sfruttasse le tecnologie 4.0, risulta interessante e in questo lavoro verrà mostrato come è stata sviluppata la stazione sia a livello meccanico che le logiche scelte a livello software. La stazione è composta da un banco di lavoro, una infrastruttura informatica realizzata ad hoc e un supporto meccanico che permette all'operatore di poter assemblare in maniera efficiente ed ergonomica il motore. A livello software la stazione sarà equipaggiata con una versione dedicata di un MES aziendale che permetterà la comunicazione in tempo reale con la produzione, il magazzino e il commerciale della azienda. Il software poi renderà disponibile una procedura guidata e controllata all'operatore, che lo affiancherà dalla prima fase di picking dei componenti da magazzino fino al termine dell'assemblaggio. Per poter verificare i passaggi effettuati dall'operatore tutti gli strumenti necessari ad assemblare il motore saranno digitalizzati e connessi al software di EDAP. Tutti i dati generati, saranno poi utilizzati per effettuare analisi sulle performance, tempistiche ed efficienza dell'assemblaggio.
EDAP 4.0 : engine digitalized assembly plant
Amadini, Matteo
2022/2023
Abstract
This paper discusses the development of EDAP 4.0, which stands for "Engine Digitalized Assembly Plant," a digitalized endothermic engine assembly station. The project was born through the collaboration between RME (Robby moto engineering), MADE, and the Politecnico di Milano above the necessity to innovate the way piston aero engines for ultralight aircraft are assembled. Nowadays, aircraft engines in this sector are assembled manually because the production volumes are very small in comparison with, for example, the automotive sector. Indicatively the most important companies have production between 20 and 90 units per day while for smaller realities productions are about hundreds of engines produced in the whole year. For example, in the automotive sector, FIAT alone produces about 2,000 engines per day. In addition, the reference regulations, DOA and POA, are very stringent. Indeed, they require very detailed procedures and documentation, from the definition of the company's organizational chart to the necessary controls over the operations carried out during production. All these factors result in a high expense of resources and low efficiency of the whole system. The development of a new methodology, taking advantage of 4.0 technologies, is of interest, and this paper, it will be shown how the station was developed both at the mechanical level and the logics chosen at the software level. The station consists of a workbench, a dedicated IT infrastructure, and mechanical support that allows the operator to be able to efficiently and ergonomically assemble the motor. At the software level, the station will be equipped with a dedicated version of a company MES that will allow real-time communication with the company's production, warehouse, and sales. The software will then make available a guided and controlled procedure to the operator, which will support him from the first stage of picking components from the warehouse to the end of assembly. In order to verify the steps taken by the operator, all the tools required to assemble the engine will be digitized and connected to the EDAP software. All the data generated will then be used to perform analysis on assembly performance, timing, and efficiency.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/208814