Advanced Non-Destructive Inspections focused on composite materials application for the automotive and marine sectors

The goal of this master thesis is to explain in detail the application of Non-Destructive-Inspection on the Automotive and the Marine sectors. Nowadays, these two particular industries faces many challenges, including increased global competition, the need for higher performance, a reduction in costs and tighter environmental and safety requirements. The materials used for these applications play key roles in overcoming these challenges. So, also an NDI procedure need to be planned in order to avoid problems during the manufacturing process and the after sale life of the structures. The entire thesis work has been done in collaboration with Vetorix Engineering.

Strumenti e metodi per il miglioramento delle performance: il pilastro TPM del Focus Improvement. Il caso Philip Morris Manufacturing & Technology Bologna S.p.A.

Le peculiarità del contesto competitivo attuale richiedono alle aziende di muoversi con la massima velocità per rispondere il più rapidamente possibile al soddisfacimento delle richieste dei clienti. La ricerca di massima flessibilità non può prescindere dall’esigenza di mantenere alti livelli di efficienza produttiva e di tendere ad un continuo miglioramento dei flussi interni. L’elaborato ripercorre i passaggi fondamentali di un progetto di miglioramento delle performance di un impianto svolto nel primo semestre 2016 presso Philip Morris Manufacturing & Technology Bologna S.p.A. La metodologia utilizzata riprende strumenti, modelli e metodi dai principi alla base del Focus Improvement, primo pilastro del tempio della Total Productive Maintenance. Attraverso l’applicazione sistematica di tecniche tipiche del problem solving (ciclo di Deming) e di approcci analitici per la determinazione delle cause di guasto (curva di Pareto, Diagramma di Ishikawa), è stato possibile identificare i principali tipi di perdite (tempo, performance, difetti qualitativi) di una macchina industriale e mettere in atto gli interventi migliorativi necessari. L’analisi si conclude con la valutazione dei futuri sviluppi dello scenario, proponendo diverse alternative a seconda dell’abilità dell’organizzazione di sostenere i risultati raggiunti o addirittura di superarli.

Evaluation of recycled carbon fibers as PLA reinforcement for additive manufacturing applications

The increased exploitation of carbon fiber reinforced polymers (CFRP) is inevitably bringing about an increase in production scraps and end-of-life components, resulting in a sharp increase in CFRP waste. Therefore, it is of paramount importance to find efficient ways to reintroduce waste into the manufacturing cycle. At present, several recycling methods for treating CFRPs are available, even if all of them still have to be optimized. The step after CFRP recycling, and also the key to build a solid and sustainable CFRP recycling market, is represented by the utilization of Re-CFs. The smartest way to utilize recovered carbon fibers is through the manufacturing of recycled CFRPs, that can be done by re-impregnating the recovered fibers with a new polymeric matrix. Fused Filament Fabrication (FFF) is one of the most widely used additive manufacturing (3D printing) techniques that fabricates parts with a polymeric filament deposition process that allows to produce parts adding material layer-by-layer, only where it is needed, saving energy, raw material cost, and waste. The filament can also contain fillers or reinforcements such as recycled short carbon fibers and this makes it perfectly compliant with the re-application of the shortened recycled CF. Therefore, in this thesis work recycled and virgin carbon fiber reinforced PLA filaments have been initially produced using 5% and 10% of CFs load. Properties and characteristics of the filaments have been determined conducting different analysis (TGA, DMA, DSC). Subsequently the 5%wt. Re-CFs filament has been used to 3D print specimens for mechanical characterization (DMA, tensile test and CTE), in order to evaluate properties of printed PLA composites containing Re-CFs and evaluate the feasibility of Re-CFs in 3D printing application.

Integration of the computer controlled screwdriver for Robotic manufacturing in the ROS environment

The computer controlled screwdriver is a modern technique to perform automatic screwing/unscrewing operations.The main focus is to study the integration of the computer controlled screwdriver for Robotic manufacturing in the ROS environment.This thesis describes a concept of automatic screwing mechanism composed by universal robots, in which one arm of the robot is for inserting cables and the other is for screwing the cables on the control panel switch gear box. So far this mechanism is carried out by human operators and is a fairly complex one to perform, due to the multiple cables and connections involved. It's for this reason that an automatic cabling and screwing process would be highly preferred within automotive/automation industries. A study is carried out to analyze the difficulties currently faced and a controller based algorithm is developed to replace the manual human efforts using universal robots, thereby allowing robot arms to insert the cables and screw them onto the control panel switch gear box. Experiments were conducted to evaluate the insertion and screwing strategy, which shows the result of inserting and screwing cables on the control panel switch gearbox precisely.

Virtual commissioning of automatic machines for mesh panels manufacturing

The purpose of this thesis is to present the concept of simulation for automatic machines and how it might be used to test and debug software implemented for an automatic machine. The simulation is used to detect errors and allow corrections of the code before the machine has been built. Simulation permits testing different solutions and improving the software to get an optimized one. Additionally, simulation can be used to keep track of a machine after the installation in order to improve the production process during the machine’s life cycle. The central argument of this project is discussing the advantage of using virtual commissioning to test the implemented software in a virtual environment. Such an environment is getting benefit in avoiding potential damages as well as reduction of time to have the machine ready to work. Also, the use of virtual commissioning allows testing different solutions without high losses of time and money. Subsequently, an optimized solution could be found after testing different proposed solutions. The software implemented is based on the Object-Oriented Programming paradigm which implies different features such as encapsulation, modularity, and reusability of the code. Therefore, this way of programming helps to get simplified code that is easier to be understood and debugged as well as its high efficiency. Finally, different communication protocols are implemented in order to allow communication between the real plant and the simulation model. By the outcome that this communication provides, we might be able to gather all the necessary data for the simulation and the analysis, in real-time, of the production process in a way to improve it during the machine life cycle.

Computer vision in aseptic pharmaceutical manufacturing: a deep learning-based approach to vial inspection and pack formation during a lyophilizer loading cycle

Vision systems are powerful tools playing an increasingly important role in modern industry, to detect errors and maintain product standards. With the enlarged availability of affordable industrial cameras, computer vision algorithms have been increasingly applied in industrial manufacturing processes monitoring. Until a few years ago, industrial computer vision applications relied only on ad-hoc algorithms designed for the specific object and acquisition setup being monitored, with a strong focus on co-designing the acquisition and processing pipeline. Deep learning has overcome these limits providing greater flexibility and faster re-configuration. In this work, the process to be inspected consists in vials’ pack formation entering a freeze-dryer, which is a common scenario in pharmaceutical active ingredient packaging lines. To ensure that the machine produces proper packs, a vision system is installed at the entrance of the freeze-dryer to detect eventual anomalies with execution times compatible with the production specifications. Other constraints come from sterility and safety standards required in pharmaceutical manufacturing. This work presents an overview about the production line, with particular focus on the vision system designed, and about all trials conducted to obtain the final performance. Transfer learning, alleviating the requirement for a large number of training data, combined with data augmentation methods, consisting in the generation of synthetic images, were used to effectively increase the performances while reducing the cost of data acquisition and annotation. The proposed vision algorithm is composed by two main subtasks, designed respectively to vials counting and discrepancy detection. The first one was trained on more than 23k vials (about 300 images) and tested on 5k more (about 75 images), whereas 60 training images and 52 testing images were used for the second one.

Cure Induced Residual Stresses on Thick Composite Components Manufactured by Additive Process

This study investigates the effect of an additive process in manufacturing of thick composites. Airstone 780 E epoxy resin and 785H Hardener system is used in the analysis since it is widely used wind turbine blade, namely thick components. As a fiber, fabric by SAERTEX (812 g/m2) with a 0-90 degrees layup direction is used. Temperature overshoot is a major issue during the manufacturing of thick composites. A high temperature overshoot leads to an increase in residual stresses. These residual stresses are causing warping, delamination, dimensional instability, and undesired distortion of composite structures. A coupled thermo-mechanical model capable of predicting cure induced residual stresses have been built using the commercial FE software Abaqus®. The possibility of building thick composite components by means of adding a finite number of sub-laminates has been investigated. The results have been compared against components manufactured following a standard route. The influence of pre-curing of the sub-laminates has also been addressed and results compared with standard practice. As a result of the study, it is found that introducing additive process can prevent temperature overshoot to occur and benefits the residual stresses generation during the curing process. However, the process time required increases by 50%, therefore increasing the manufacturing costs. An optimized cure cycle is required to minimize process time and cure induced defects simultaneously.

Characterization Of Single Use Reactor Used For The Manufacturing Of Formulated Products Within The Pharmaceutical Industry

Mixing is a fundamental unit operation in the pharmaceutical industry to ensure consistent product quality across different batches. It is usually carried out in mechanically stirred tanks, with a large variety of designs according to the process requirements. A key aspect of pharmaceutical manufacturing is the extensive and meticulous cleaning of the vessels between runs to prevent the risk of contamination. Single-use reactors represent an increasing trend in the industry since they do not require cleaning and sterilization, reducing the need for utilities such as steam to sterilize equipment and the time between production batches. In contrast to traditional stainless steel vessels, single-use reactors consist of a plastic bag used as a vessel and disposed of after use. This thesis aims to characterize the fluid dynamics features and the mixing performance of a commercially available single-use reactor. The characterization employs a combination of various experimental techniques. The analysis starts with the visual observation of the liquid behavior inside the vessel, focusing on the vortex shape evolution at different impeller speeds. The power consumption is then measured using a torque meter to quantify the power number. Particle Image Velocimetry (PIV) is employed to investigate local fluid dynamics properties such as mean flow field and mean and rms velocity profiles. The same experimental setup of PIV is exploited for another optical measurement technique, the Planar Laser-Induced Fluorescence (PLIF). The PLIF measurements complete the characterization of the reactor with the qualitative visualization of the turbulent flow and the quantitative assessment of the system performance through the mixing time. The results confirm good mixing performances for the single-use reactor over the investigated impeller speeds and reveal that the filling volume plays a significant role in the fluid dynamics of the system.