LEVEL-UP has developed an operational and refurbishment framework relevant to new and existing manufacturing equipment to extend the lifetime through optimized dynamic utilization, improved maintenance practices, and application of remedial actions i.e. upgrade, repair, remanufacturing, refurbishment when needed.
The backbone of LEVEL-UP operational framework is a service oriented scalable digital platform offering a wide variety of capabilities and services for improving maintenance practices and optimizing dynamic utilization. For legacy industrial equipment to benefit from Industry 4.0 the first step is to apply modernization actions enabling interoperability and data sharing. LEVEL-UP system includes diagnostic & prognostics modules for predictive maintenance (PdM) application which plays a crucial role in this process. Sensor/Gateway layer, Middleware, Semantic Mediator, Machine forecasting, failure mode effects analysis, decision support tool, and detect & predict are components that work closely together. The return on assets (RoA) model allows to evaluate different scenarios from an economic perspective, concluding that affordable modernisation investments can be good alternative to machine replacement and increase useful time at machine level.
Besides modernisation through digital technologies, retrofitting packages combining mechatronics upgrades with virtual simulators and/or control, add new functionalities to the machines, e.g. improved accuracy and performance in specific industries avoiding obsolescence. In addition, in-line metrology and inspection packages based on fibre optics sensors or vision, are available for monitoring product quality and machine status. They also improve performance by significantly reducing manufacturing and quality control times while increasing the knowledge about the state of the machine.
The project has explored the potential of Additive Manufacturing to create sustainable processes focused on the recovery of high-value metal components, enhancing the pillars of sustainable development. An integrated workflow has been developed combining the use of scanning technologies to create digital models of damaged components for diagnosis, CAAP tools to design and optimize the printing process and ensure consistent quality, and simulation to perform feasibility studies in terms of cost, safety and support the selection of the most appropriate manufacturing technique for a given situation. At component level, repair technologies based on metal 3D printing have demonstrated to support lifetime extension and more economic and resource efficient than other alternatives.
LEVEL-UP provides a common strategy for applying circular economy principles to industry through the definition of 8 strategies and 10 circularity protocols. LEVEL-UP circularity protocols help manufacturers and/or OEMs to retrofit their equipment applying actions, process, and digital technologies and advanced manufacturing methods in a proper way. A CEN-CENELEC Workshop LEVEL-UP on this topic, Circularity Protocols for extending the useful Life of Large Industrial Equipment, for the elaboration of a CWA is the main contribution of the project to standardization.
Overall, 54 exploitable results have been identified, 26 will be commercialised by 14 partners. A strong dissemination strategy was followed promoting LEVEL-UP results to targeted audiences by utilising the project’s existing channels (Website, YouTube, Twitter, LinkedIn). Also, thematic workshops and the final conference were organised, creating spaces to make LEVEL-UP technologies accessible to industry and the research community. Together with enhanced exploitation models supported by the EC tools provided in the HRB and the participation in the DFA (Digital Factory Alliance) marketplace , allows the project to achieve visibility outside the consortium framework.
