Hybrid EMAT-Vision solution for OPTImisation of advanced manufacturing process of automotive tailor welded BLANKS

Projektinformationen

OPTIBLANKS

ID Finanzhilfevereinbarung: 778392

DOI

10.3030/778392

Projekt abgeschlossen

EK-Unterschriftsdatum 3 August 2017

Startdatum 1 September 2017

Enddatum 31 August 2019

Finanziert unter

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Gesamtkosten

€ 1 637 375,00

EU-Beitrag

€ 1 146 162,50

Koordiniert durch

INNERSPEC TECHNOLOGIES EUROPE SL
Spain

Periodic Reporting for period 2 - OPTIBLANKS (Hybrid EMAT-Vision solution for OPTImisation of advanced manufacturing process of automotive tailor welded BLANKS)

Berichtszeitraum: 2018-09-01 bis 2019-08-31

Zusammenfassung vom Kontext und den Gesamtzielen des Projekts

Tailor Welded Blanks (TWBs) are implemented wherever a vehicle needs to be safer and lighter. These structural parts are made out of two or more separate pieces of flat material, dissimilar thickness or mechanical properties, welded together before being stamped to provide customized and superior qualities. Seam-welding is considered the most critical step of the TWBs manufacturing process and weld-defects result in the majority of TWB part rejections, costing European automotive manufacturers more than 9.000 Tons of wasted materials/year.
In order to optimize part rejection criteria, reduce manufacturing costs and eliminate broken parts during the TWB manufacturing process Innerspec, the global leader in automotive TWB inspection, is developing OPTIBLANKS, a hybrid novel solution which combines two non-destructive inspection technologies for weld seam quality control.
The OPTIBLANKS project main objective is to optimize the TWB welding process by reaching over 95% defect detection (therefore, enhancing TWBs quality and safety), increasing inspection speed up to 60 m/min, reducing inspection costs by 50% (reducing materials waste and fulfilling all inspection requirements with a single solution) and providing TWBs manufacturers with valuable process control data.

Arbeit, die ab Beginn des Projekts bis zum Ende des durch den Bericht erfassten Berichtszeitraums geleistet wurde, und die wichtigsten bis dahin erzielten Ergebnisse

During OPTIBLANKS project, Innerspec has successfully completed all tasks foreseen in the work plan including system validation during onsite trials at customer facilities.
At project launch, Innerspec carried out a study gathering all defects likely to appear in welds during the seam welding process. This process was based in multiple information provided by end-users over the last years. Based on this information and customer feedback, Innerspec confirmed the optimal components to be used in the final hybrid architecture.
In parallel to the selection and optimization of hardware, Innerspec completed the new Hybrid software architecture and developed advanced signal processing and decision-making algorithms to reach a probability of detection close to 100%.
Once these tasks were completed, Innerspec merged and comprehensively tested the OPTIBLANKS final software and hardware using TWBs from production plants. Trials were performed in order to find incompatibilities and mitigate them. At this stage of the project, Innerspec also developed the results analysis intelligence.
After laboratory validation, Innerspec fully tested OptiBlanks system at TWB manufacturing lines, thanks to these on-site trials, Innerspec has been able to fine tune the inspection system and develop a solution which fully meets end-users requirements which is now ready to be commercialized.
Regarding the optimization of OPTIBLANKS manufacturing model, Innerspec has negotiated with OEMs to optimize system costs. Furthermore, lead times and stock availability have being analysed in order to secure product launch. In addition to this, a variety of promotion and distribution models have also been defined.
On the commercial side, Innerspec has been very active along OptiBlanks project. Some of the dissemination activities carried out include:
- Creation of a dedicated OptiBlanks product website: www.optiblanksproject.eu
- Attendance to different industry related events, fairs and brokerage events to promote the novel solution among end users.
- Different posts in LinkedIn related with project progress.
- Development of a dedicated OptiBlanks area at Innerspec’s website.
- Creation of a YouTube channel to showcase OptiBlanks’ promotional videos.
- Development of technology explanatory video and publication in YouTube and project website.
- Development of project brochure and dissemination across several industry relevant associations in Spain and Europe.

Fortschritte, die über den aktuellen Stand der Technik hinausgehen und voraussichtliche potenzielle Auswirkungen (einschließlich der bis dato erzielten sozioökonomischen Auswirkungen und weiter gefassten gesellschaftlichen Auswirkungen des Projekts)

On average, between 5-9 TWBs are utilised for each light vehicle, resulting in a production of 120 million TWBs in Europe and 200-250 million TWBs worldwide per year. This represents an estimated annual consumption of more than 300.000 Tons of raw materials.
In order to optimize the TWB manufacturing process, reduce raw material scrap rate and optimise material usage, the industry requires 100% inspection of autogenously laser welded parts to identify defects.
Nowadays, TWB manufacturers need to use different inspection technologies from different providers in order to ensure weld quality control, leading to cost increase and longer production line shutdowns due to maintenance works and rejection rate increase, as well as increased part rejection rates.
OptiBlanks will reduce materials waste leading to economical direct savings of more than 50.000€ per system per year and will reduce inspection costs by 50%.
TWB manufacturing lines with independent inspection systems installed in series show a scrap rate ranging 2-3%, due to the addition of systems false-positive rates. On average, this signifies 85.000€ of material loss per year per welding line. With an integrated Hybrid system, the interpretation of both technologies will be merged into a single processor and the discrimination algorithms will help to optimize material usage. Furthermore, when results from Hybrid technology are used to set welding parameters, the current manufacturing scrap rate can be reduced down to 0.5% or less.
OptiBlanks will guarantee TWBs high quality, allowing manufacturers to provide products meeting the most stringent standards thus avoiding customer claims or returns when weld quality is not enough to resist stamping process. Most importantly, high quality materials will avoid that defective parts reach our cars, securing car frame structural strength in accidents.

OptiBlanks system at Innerspec's facilities

OptiBlanks system installed at a Tailor Welded Blanks manufacturing line