United Kingdom-Nottignham: Miscellaneous special-purpose machinery
Section I: Contracting authority
Main address: https://www.nottingham.ac.uk/
Address of the buyer profile: https://in-tendhost.co.uk/universityofnottingham/aspx/Home
Section II: Object
Future Automated Aerospace Assembly Demonstrator Phase 2 (FA3D2) Concept
The Centre for Aerospace Manufacturing (CAM) at the University of Nottingham (UoN) works with partners from across the UK and European aerospace industry to deliver industrially focused research into aerospace assembly systems. Advanced manufacturing is a key research priority area for Nottingham and the University has invested significantly in this research. The University made a strategic investment in automated assembly infrastructure through the Future Automated Aerospace Assembly Demonstrator (FA3D) project, which was commissioned in 2016. Based on the success of this project, funding has been secured from the UK Government’s Industrial Strategy Challenge Fund (ISCF) through the Aerospace Technology Institute (ATI) for development of the second phase of this demonstrator.
Modelling and simulation
The minimum requirements of 3D modelling and simulation to enable virtual commissioning are as follows:
(a) all automation, tooling and associated control equipment must be modelled in 3D in the desired CAD package or supplied in the required format as set by UoN — as a minimum, the supplied solution must be able to accept CAD models in CATIA V5 R2017 as an input and be able to output to a compatible format. This requirement does not constrain the format used internally for the digital twin, and suppliers are free to recommend their preferred modelling and simulation package for that purpose;
(b) the CAD model must be supplied with embedded forward and inverse kinematics to enable simulation and verification of the FA3D2 and its associated processes;
(c) all acceleration and speed parameters must be set in the kinematics assemblies within the model to enable real time simulation and motion visualisation;
(d) process positions must be set within the kinematics for process specific positions such as home or closed for tooling clamps, etc.;
(e) smart devices must be generated to simulate actual device behaviour and enable PLC off-line programming;
(f) a post processor must be supplied to enable realistic simulation and off-line programming of the FA3D2 and its automated processes;
(g) a full process and method, along with suitable training data where possible, must be supplied to enable UoN users to generate off-line programmes for the automated processes including PLC code generation and verification;
(h) the supplier must demonstrate their 3D simulation and virtual commission capabilities and any previous implemented solutions within their tender submission;
(i) the installed system must be in accordance with the framework and requirements set out in work package 2: smart manufacturing and in collaboration with the successful tenderers of WP2.2 IoT Network Infrastructure, WP2.3 Digital Twin, and WP2.4 data analytics and machine learning.
A minimum of 12 month warranty is required.
ISCF Funding (Industrial Strategy Challenge Fund)
The minimum requirements of the IoT network infrastructure to enable real-time data acquisition, management and visualisation via interactive dashboards/HMIs are as follows. See Figure 8 for the data acquisition IoT architecture example. a. The system must enable the user to capture data gathered from all intelligent sensors and metrology devices specified in Work Package 5: Precision Assembly, or data from a selection of these sensors. o The data from the sensors must be categorised within the data store to perform analysis in order to gain insights into the automated processes. o The supplier must give UoN access to this data both programmatically through an API (Application Programming Interface) and through an interactive dashboard interface. b. The installed system must be capable of presenting real-time information (of pre-selected process data captured by sensors) to the user via interactive dashboards on an HMI device (number of interfaces to be agreed). o These dashboards must be easily re-configurable and enable the user to view, select, edit, load and export process parameters. c. The supplier must provide UoN with the ability to build its own interactive dashboards to visualise data from sensors and automated equipment. Access to baseline code is required wherever possible. d. The installed system must be able to capture, store and re-call all historic process sensor data from the data store and know when (time and date) processes were carried out. e. The supplier must connect to all required process sensors, PLCs and/or devices to enable data acquisition. f. The installed system must be in accordance with the framework and requirements set out in Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of WP2.1 Modelling and Simulation, WP2.3 Digital Twin, and WP2.4 Data Analytics and Machine Learning.
A minimum of 12 months Warranty is required
The minimum requirements for digital twin generation are follows. See Figure 7 for the basic FA3D2 digital twin architecture and Figure 9 for the example FA3D2 digital twin minimum data flow. a. The supplier must provide an architecture diagram with their tender proposal, which illustrates their digital twin concept, hardware, software, and data flow. b. The supplier must provide a connected system, which enables bi-directional communication and visualisation of sensor and automation data. Systems within the cell must be able to access related messages from sensors or devices. These tags/messages will be used to trigger other events within the cell or instruct data to be extracted, transformed and loaded (ETL) at specified real-time interval/s. c. The supplier must provide UoN with the required architecture to enable a digital control room interface/dashboard which enables users to view/perform the following: a. Real-time visibility of KPIs and issues for proactive problem resolution - supplier to suggest their achievable frequency. b. Drill down into underlying line asset data for root-cause analysis and continuous improvement - supplier to demonstrate workflow. c. Automatic notification (text, email or equivalent) when a machine signal or KPI deviates from normal behaviour - supplier to demonstrate proposed concept for alerts referring to server, tag, device, or machine issue d. Trend any PLC tag in minutes - time stamp, name and value in an open format etc. e. Enable remote troubleshooting of PLC issues. f. Connect to existing factory assets via the installed micro server and/or gateway. g. Send and revision control robot programs to the required controllers for execution. h. Visualise the physical automated process running within the virtual environment - real time (supplier to specify frequency), this must be via a mobile tablet or other device proposed by the supplier such as augmented headset device. d. The supplier must provide an example of how a digital work instruction can be generated, published and visualised by the operator. e. UoN will require the capability to capture data within the digital work instruction. The supplier should demonstrate how process parameters can be captured within the instruction and ETL for future analysis. f. The installed system must be in accordance with the framework and requirements set out in Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of WP2.1 Modelling and Simulation, WP2.2 IoT Network Infrastructure, and WP2.4 Data Analytics and Machine Learning.
A minimum of 12 months warranty is required
Data Analytics and Machine learning
The minimum requirements for data analytics and machine learning are as follows: a. All process data captured must be extractable in an open format such as comma separated variable file format (.csv) or XML, XLS, XLSX, PDF, TXT that can be opened within freely available text editing software. b. Data collected and exported will be analysed by running machine learning algorithms. The installed system must have the function to import the data back into the installed system and automatically update the process variables. c. The installed system must be capable of capturing and categorising in-process measurements and program data. This must enable UoN to complete real-time modifications of programs. d. The installed system must be in accordance with the framework and requirements set out in Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of WP2.1 Modelling and Simulation, WP2.2 IoT Network Infrastructure, and WP2.3 Digital Twin
ISCF Funding (Insutrial Strategy challenge fund)
Reconfigurable cell floor
Size and Configuration: a. Size of reconfigurable floor area of cell shall be 18 metres by 6 metres. b. Width of cell shall be 6 metres unless there are other requirements from WP3.3 Reconfigurable Cell Automation at Height. c. Reconfigurable floor area shall be able to be used as a single cell or divided into at least two separate cells that can operate independently. d. Reconfigurable area shall be capable of being set up for different uses and production cell sizes as specified in the product architectures outlined in Section 4.1. e. When floor is configured into multiple individual cells, it shall be possible to safely have manual operations taking place in one cell while automated operations are taking place in the other. f. System shall be capable of being reconfigured between any of the required configurations for the product architectures set out in Section 4.1 within 7 hours (1 shift). g. Any element that needs to be moved shall be capable of being lifted with an overhead crane or forklift truck. h. Reconfigurable floor must locate onto existing floor level and not require excavation or additional reinforcing. It is acceptable to fasten into the existing floor. i. Floor system shall not inhibit access for wheeled vehicles such as fork lift trucks, trolleys or mobile robots. j. The floor must be supplied with full instructions, risk assessments and training to enable safe and efficient reconfiguration of the floor system by the system owner. k. The design of the flooring system shall be such that it is possible to extend in future. Physical Integration and Functional Requirements: l. Floor system shall allow physical integration of the following: o Existing automation equipment (see Section 6) o Automated platforms provided as part of WP3.2 Automation Platforms o Tooling for holding, positioning and assembling aerospace structures m. Floor system shall have dedicated features to enable laser tracking to determine relationship to cell level reference co-ordinate system. n. Structure of the reconfigurable floor and attachment points shall be designed such that they are capable of withstanding the operational loads of the automated equipment, when running in automated mode at full speed with the maximum allowable payload. Service Provision and Connectivity: o. Floor system must allow digital integration of both existing equipment (see Section 6) and all automation platforms provided as part of WP3.2 Automation Platforms, in line with the requirements of WP2 Smart Manufacturing and in collaboration with the successful tenderers of Work Package 2: Smart Manufacturing sub work packages. p. Floor system shall communicate with cell smart manufacturing system, identifying for each location what is installed and what services are in use. q. Floor system shall provide each location point on the floor with a connection to all services including electrical and pneumatic power, extraction, communications and any other services as required by Work Package 2: Smart Manufacturing, Work Package 3: Reconfigurable Automation and Work Package 5: Precision Assembly. r. All services shall be provided such that there are no trailing cables, pipes etc. running across the floor. s. All services must be safely installed in accordance with all relevant standards and legislation. t. Connections to all services shall be designed such that any combination of them can be used at any location (including locations that require no services). u. The system as provided must comply with all relevant health and safety regulations and legislation and shall be CE marked. v. System must allow integration with the overall safety system as provided in WP3.4 Safety Systems.
Minimum of 12 months warranty is required
ISCF Funding (Industrial strategy challenge fund)
a. Two automation platforms shall be provided with all control systems, pendant and drive modules required. b. The control systems shall be capable of allowing each automation platform to be used independently or together. c. The two automation platforms offered do not need to be the same brand, type or have the same specification. d. The supplier shall provide the control software with high level programming language for basic robot program design. e. PLC system shall be provided for control of automation platforms and end effectors. f. PLC must be connected to smart manufacturing system in accordance with the framework and requirements set out in Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of WP2.1 Modelling and Simulation, WP2.2 IoT Network Infrastructure, WP2.3 Digital Twin, and WP2.4 Data Analytics and Machine Learning. g. Provision of end effectors is excluded from this tender. Existing end effectors at UoN are outlined in Section 6. Further details of existing end effectors and tool changers shall be given once the tender is awarded. The existing drilling end effector shall be used to demonstrate automation platform operation. h. Provision of tool changers is excluded from this tender. Existing tool changers at UoN are outlined in Section 6. Further detail on existing tool changers at UoN shall be provided once work package has been awarded. i. Automation platforms shall be capable of payloads of up to 250kg and positional accuracy of ±0.25mm or better. j. Automation platforms will be used in a reconfigurable assembly cell and shall be capable of being moved easily and quickly i.e. shall have no permanently fixed connections to the floor, power, communications or other services. Options for the position of and connection to automation control cabinets shall be included by the tenderer as part of the solution for reconfigurability. k. Automation platforms shall provide all services to existing tool changers and end effectors including electrical and pneumatic power, communications and vacuum extraction. l. All services to the robot flange or equivalent shall be housed within a dress pack or equivalent to prevent snagging with other equipment in the cell. m. Automation platforms shall be able to be lifted and moved both with and without the use of an overhead crane. A forklift truck will be available within the facility. n. Automation platforms provided shall be able to have off line programs created through both Visual Components and Delmia. o. The platforms as provided must comply with all relevant health and safety regulations and legislation and shall be CE marked. p. Solutions offered shall complement and extend the current automation capability of UoN, not duplicate existing equipment (see Section 6). Opportunities to extend current capability could include: o Payload o Reach o Accuracy Improved or updated kinematics Advanced calibration Built in measurement system or machine vision Metrology assisted o Portability o Provision for data capture o Machine learning o Force feedback o Collaborative or slave-master capability q. System must allow integration with the overall safety system as provided in WP3.4 Safety Systems. r. The automation platforms must be supplied with full instructions, risk assessments and training to enable safe and efficient operation and reconfiguration of the platforms by the system owner.
A minimum of 12 month warranty is required
Reconfigurable Cell Automation at Height
a. System shall be capable of covering a working volume of 18m x 6m at a height of up to 5m, in alignment with the reconfigurable floor working area as set out in WP3.1 Reconfigurable Cell Floor. b. System shall be capable of positioning a payload of minimum 50kg over the working volume. Typical payload shall be large volume metrology system, end effector, or lightweight robot. c. Systems that do not cover the entire volume specified may be considered if they offer some particular advantage e.g. flexibility, low cost, high accuracy etc. d. System shall be capable of positioning its payload accurately, with a positional tolerance of ±0.25mm. e. System delivery and installation shall include integration with one of the existing systems at UoN to demonstrate functionality. This shall be decided by UoN after the work package is awarded. f. System shall provide all services to robots, end effectors, or metrology mounted on them, including electrical and pneumatic power, communications and vacuum extraction. These items are listed in Section 6 and further details of existing metrology systems, end effectors and tool changers shall be provided by UoN after tender award. g. If fixings are required, the system shall fasten to the factory floor. Details of the factory floor will be provided on request. h. System shall be provided with all control systems, pendant and drive modules required. i. The supplier shall provide the control software with high level programming language for basic program design. j. PLC system shall be provided for control of system. k. PLC must be connected to smart manufacturing system in accordance with the requirements set out in Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of WP2.1 Modelling and Simulation, WP2.2 IoT Network Infrastructure, WP2.3 Digital Twin and WP2.4 Data Analytics and Machine Learning. l. The system must include safety solutions for working with the reconfigurable floor such that if the floor is configured as two cells, the system can work in one while manual operations are taking place in the other. m. The system as provided must comply with all relevant health and safety regulations and legislation and shall be CE marked. n. System must allow integration with the overall safety system as provided in WP3.4 Safety Systems. o. The system must be supplied with full instructions, risk assessments and training to enable safe and efficient operation and reconfiguration of the system by the system owner.
a. Design of a safety system must meet the demands of the reconfigurable cell as per WP3.1 Reconfigurable Cell Floor, WP3.2 Automation Platforms and WP3.3 Reconfigurable Cell Automation at Height and in collaboration with the successful tenderers of those work packages. Safety system shall cover at least the working volume of the cell (18m long x 6m wide x 5m high). Safety system shall also be capable of operating in conjunction with existing equipment at UoN (see Section 6). b. Safety systems must be integrated into the digital infrastructure as set out in Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of Work Package 2: Smart Manufacturing sub work packages. c. Supply must include safety PLC and physical safety systems such as, but not limited to, guards, fencing, shields, dividers, light curtains and area scanners, E stops, and relevant ancillaries. d. The safety system as provided must comply with all relevant health and safety regulations and legislation and shall be CE marked. e. Safety systems shall be easily and quickly reconfigurable to meet the cell demand. Whole cell reconfiguration time is 7 hours (1 shift) and safety system reconfiguration shall be completed within that time. f. Solution shall include digital modelling and simulation capability for system set up and ability to design and model new set ups as required, in conjunction with WP2.1 Modelling and Simulation. g. In accordance with all relevant legislation, system shall be capable of managing different levels of access to the cell including: o No human access to any part of cell, enabling fully automated operation o Zoning of the cell so that part of it can be accessed by humans while the other part is in full automated operation o Zoning of the cell into 2 independent assembly cells o Human and robot working together e.g. for commissioning, testing etc. o Intermittent human access to the cell to carry out a manual operation without triggering automation e-stop h. The system must be supplied with full instructions, risk assessments and training to enable safe and efficient operation and reconfiguration of the system by the system owner.
Large Volume Measurement Equipment
a. Equipment shall have facility for multipoint simultaneous tracking over volume 18m long x 6m wide x 5m high at accuracy 0.10mm, in line with the method set out in ISO/IEC GUIDE 98-3:2008 Evaluation of measurement data, guide to uncertainty in measurement. b. Equipment shall have the ability to measure surfaces, edges and features such as holes, slots and pins. c. Equipment shall have the ability to measure parts with different surface finishes including carbon fibre bag face, carbon fibre tool face, bare metal (e.g. aluminium and titanium), primed material and top coat painted material. d. Equipment shall have the ability to compensate for variation in temperature and humidity (21oC ±5, 40-60 %) without compromising measurement quality. e. Equipment must have the ability to integrate into cell digital infrastructure (required standard/communications protocol will be available) in line with Work Package 2: Smart Manufacturing. f. Equipment must have the ability to be used in conjunction with WP3.2 Automation Platforms and existing equipment at UoN (see Section 6) for robot calibration and path correction. Equipment provider shall be responsible for any integration with the automation platforms of WP3.2 Automation Platforms and those existing at UoN (outlined in Section 6). g. Equipment shall be easy and quick to move and set up in different cells for different measurement types, target set up time is between 1 and 2 hours. h. Measurements shall be able to be taken and data analysed through Polyworks, Spatial Analyser and also on equipment’s own proprietary software. i. Equipment shall be able to be automated through scripting. These automation scripts shall both be accessible to operators through an HMI and to the cell digital infrastructure through an API. j. Supply must include a calibrated measurement standard e.g. length bar or artefact. k. Supply must include training and associated training material for UoN staff l. Supply must comply with all relevant health and safety regulations and legislation and shall be CE marked.
Measurement processes and Integration
In conjunction with University of Nottingham staff, supplier shall: a. Carry out evaluation of existing equipment (see Section 6) against technical requirements for measurement assisted assembly: o Use of Nikon Laser Radar, Leica Laser Tracker plus T-Scan, T-Mac & T-Probe, Nikon K-CMM + K-Robot & Multi Sided Probe o Use of equipment purchased in WP5.1 Large Volume Measurement Equipment o Use of currently available software Spatial Analyser, Polyworks and system proprietary software o Produce report on evaluation outcomes, capability and best practice b. Develop and implement cell master datum structure in conjunction with WP3.1 Reconfigurable Cell Floor, WP3.2 Automation Platforms, and WP3.3 Reconfigurable Cell Automation at Height. This will include Enhanced Reference System (ERS) fixed Reference Points (RP), and repeatable measurement positions as well as requirements for jig points on future fixtures. This must enable UoN to reconfigure between different cell layouts and set up / book into cell master datum structure as required in future. c. Provide support for integration of equipment control at cell level in conjunction with Work Package 2: Smart Manufacturing, including definition of standard interfaces. d. Develop capability for import and export of data from and to other software such as digital twin (WP2.1 Modelling and Simulation and WP2.3 Digital Twin), MES, IoT platform (WP2.2 IoT Network Infrastructure), data analytics software (WP2.4 Data Analytics and Machine Learning) etc. e. Provide an approach for uncertainty evaluation for cell set up f. Develop and provide an approach to automate measurement processes, and integrate with other processes and equipment within the cell: o Automated non-contact routine for gap measurement and analysis o Automated in process feature measurement e.g. sealant bead monitoring o Integration with robotic equipment g. Develop and provide an approach using post processing metrology software for: o Field level control o Comparison to CAD data o Interrogation of measured data, including point clouds h. Further to automation requirements in other points within this work package, equipment shall be able to be automated through scripting. These automation scripts shall both be accessible to operators through an HMI and to the cell digital infrastructure through an API. i. Provide an industrial PC for software, data storage and export, if required. j. Develop and provide best practices processes, training and user manuals in conjunction with staff at UoN to ensure processes can be replicated for multiple different parts and projects. k. Develop and demonstrate process for measurement of assembly build quality. At each stage of the assembly process the metrology system should be able to monitor the build quality and compare to the CAD reference model. l. Develop and demonstrate measurement of parts to confirm manufacturing conformance, taking into account component positional accuracy in the jig.
ISCF funding (Industrial Strategy Challenge Fund)
Improving Accuracy of Robotics with External Metrology
General a. System must work with and have communication interface for the existing industrial robot controllers (see Section 6) and for any automation platforms forming part of WP3.2 b. System shall have provision for interfacing with additional robots at a later date. c. System may make use of metrology equipment available (see Section 6) and metrology equipment purchased in as part of WP5.1 Large Volume Measurement Equipment. d. System must have the ability to integrate equipment control at cell level in accordance with Work Package 2: Smart Manufacturing and in collaboration with the successful tenderers of Work Package 2: Smart Manufacturing sub work packages. e. Supply must include training and associated training material for UoN staff. Robot Calibration f. Systems must have the facility in conjunction with external metrology to complete measurement routine to perform a level 2 calibration on a robot in order to gain an accurate kinematic model for use in offline programming and compensation. g. This must comply with the requirements in Work Package 2: Smart Manufacturing. h. System shall be capable of increasing positional accuracy of robot to <0.1mm. Robot End Point and Path Correction System shall provide linkage between external metrology and industrial robotic platforms: i. System shall be programmable for different processes i.e. part positioning, drilling, fastening and riveting as well as different product architectures and cell set ups a. Processes shall be easy and quick to set up, (less than 4 hours) j. System shall work with defined data standards. It shall have the ability to import multiple data types (e.g. CATIA, other CAD, robot OLPs) into the system, perform data capture and acquisition throughout the process, and output data in multiple formats (coordinates/commands for robot controllers and for use in analysis, CATIA, Excel, comma-separated value, .xml etc.) k. System shall provide means of creating offline robot paths or be able to upload externally created ones. l. System shall be capable of accommodating metrology that will enable a working volume of the ABB and KUKA robots (outlined in Section 6) in fixed positions but with any cell configuration m. System shall aim to increase robotic end point to accuracy of 0.1mm n. System shall increase path accuracy to 0.2mm at a working speed of 50mm/s
A minimum warranty of 12 months is required
ISCF Funding (Industrial Stategy Challenge Fund)
a. System offered should be a TRL 3-6 product that offer a step change for metrology assisted assembly processes in industrial environments, suitable for beta testing. b. System should focus on achieving similar results to WP5.1 Large Volume Measurement Equipment and WP5.2 Measurement Processes and Integration, through leveraging o Time, cost, quality, scope c. System should address a particular areas of interest for UoN (alternatives may be considered): o Decreasing the cost of a system through the use of low cost sensors o Increasing the quality of measurement through sensor fusion o Automation, integration and development of robust processes o Target-less non-contact feature measurement o Embedded metrology devices in jigs and tooling o Application of metrology and processes previously used in other industries and to aerospace o Increasing accuracy of hole measurement o Use of machine vision to correct robot path or end point accuracy d. Supplier shall provide detailed expectation of specification and business case for how the new technology meets challenges of aerospace assembly, as well as proposed plan for testing and demonstration e. Development & instruction in conjunction with staff at UoN to ensure processes can be replicated for multiple parts & projects f. Delivery of system in line with specification to be jointly agreed between UoN and supplier at point of contract award. g. Supply must include training and associated training material for UoN staff
Section III: Legal, economic, financial and technical information
Please see tender documents.
Section IV: Procedure
Section VI: Complementary information
Internet address: http://www.nottingham.ac.uk
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