Manufacturing
The manufacturing industry covers the design, manufacture and processing of products (parts, components or equipment) for many different sectors of the economy: from extraction to distribution of materials; from production to marketing and use of products. It has three components:
- metal processing, including metal working and tooling;
- equipment, including machines, production systems and components;
- precision instruments, including optical instruments and measuring instruments.
Carnot Institutes strongly involved
Examples of partnerships with companies in the sector
A connected washer providing contactless control over nut tightening in aero engines
Partnership Carnot Cetim - JPB SystèmeJPB Système has teamed up with Cetim to meet the needs of the aeronautical industry by reducing the time aircraft need to spend on the ground checking that nuts are properly tightened.
A connected washer providing contactless control over nut tightening in aero engines
Supporting Innovation
Significant progress has already been made in contactless control over nut tightening in the nuclear industry and rail transportation in a context of vibrations and sharp changes in temperature. However, in the aeronautical industry, JPB Système is pioneering a similar solution for aircraft engines that combines simplicity, speed and accuracy. The company, which is already a leader in self-locking nuts, has leveraged its in-house operational expertise of the Internet of Things (IoT) to come up with a connected washer that is resistant to electromagnetic interference and displays the required torque in just one second. Measurement accuracy to within 6% may be obtained from 10 cm away, whereas an operator using a traditional method achieves 10% at best. Such performances significantly reduce the time for which aircraft are out of action performing checks on their engines.
©Cetim
The client needs
JPB Système is a young family-owned business, created specifically to come up with secure nut tightening solutions for leading aero engine manufacturers. Beginning in 2009, the SME began innovating and robotizing its production processes and making them self-adaptive by harnessing technology such as the Internet of Things (IoT). Its ability to rapidly turn out a range of customised, affordable fixing or sealing solutions has allowed the business to grow rapidly and move into the international market. To come up with a solution that provides quick and accurate contactless checks over nut tightening, JPB Système’s teams leveraged all their experience of the IoT as well as acquiring new expertise. In particular, strain gauges were inserted into washers in partnership with the Carnot Cetim mechatronics resource centre. The Company was able to harness all of Cetim’s human and technical resources to prove the effectiveness and performance levels of its connected washers. Aside from technological considerations, Cetim was able to tap into JPB Système’s corporate DNA by helping to maintain the degree of responsiveness to, and the fit with end user needs.
Partnership
The Carnot Cetim Institute partners businesses in the mechanical engineering sector, particularly where a high level of mechatronics expertise is required. Mechatronics incorporates the electronic systems that are so indispensable to the intelligence embedded in mechanical engineering equipment. These can then be linked to service functions. This mechatronics expertise has enabled Cetim teams to partner the development of a washer that actually helps to mechanically tighten nuts. In particular, to measure torque, it was necessary to produce a machined test body to position the strain gauges while integrating the communication device. The reader developed by the JPB Système teams is installed on a laptop placed a few centimetres from the nut. The screen takes just one second to display the axial tension measured by the washer, which is remotely powered by a passive system to eliminate all electromagnetic interference. A first 12 mm diameter washer was presented at the 2019 Salon du Bourget trade fair. Over the coming months, work will be performed to optimise the electronic systems and enable the partnership to market washers of different diameters. JPB Système is meeting the challenge of measuring required torque at any given time for one of its customers.
The design of a comfortable and reliable stand-alone climb assist system allows FIXATOR to target the world wind energy market
Partnership ARTS Carnot Institute - FIXATORExolift helps reduce arduous maintenance occupations. The culmination of three years' research, including two year research collaboration with ARTS Carnot Institute, has led to its market uptake.
The design of a comfortable and reliable stand-alone climb assist system allows FIXATOR to target the world wind energy market
Supporting Innovation
The climbing of vertical access ladders by workers to reach elevated surfaces, such as pylons or wind turbines, for inspection requires intense muscular efforts. French SME FIXATOR, a specialist in the manufacturing of suspended platforms and lifting winch for hoisting and lowering persons and equipment, have underscored the intent of their design around the technician’s morphology. While the latter’s weight is being taken into account, continued assistance is provided and adjusted based on the technician’s speed. The climb assist system taking about 80% off the user weight, he is therefore able to adapt his speed of ascent / descent accordingly without tiredness and in better safety conditions. Indeed, the transportable system’s strap is fixed to a rigid part of the ladder. With an autonomy averaging between 8 to 10 return trips over an 80 m-distance, Exolift shows an ascend / descend time divided by 3 and physical effort required divided by 5.
The client needs
Based in the Loire region (Angers, Western France) FIXATOR started 90 years ago with the development of permanent / temporary suspended working platform and lifting winch design. The SME’s solutions are distributed worldwide through and extensive network of distributors. FIXATOR R&D teams took the chance to innovate while meeting burgeoning demands notably for installation activities and maintenance of wind turbines. The argument put forward was that swift action was needed to respond to such demand at international level, as it was outgrowing the French orders. This new idea entailed to work out an adequate and reliable climb assist systems. Its integration into existing installations has been facilitated through new technologies. The great benefits with such system are: autonomy of use, drudgery reduction, cost-efficiency, enhanced productivity.
Assistance by AMVALOR over 2 years, a subsidiary of Arts et Métiers Paris Tech and a part of the ARTS Carnot Institute, has brought forward the development of Exolift.
Partnership
The ARTS Carnot institute focus on the design, industrialisation and production of innovative and complex manufactured goods with multiple technologies. To meet FIXATOR’s expectations effectively, the Arts et Métiers Paris Tech researchers have worked for optimising the demands on weight, performance and costs. They also designed the measuring chain to control the speed of travel using a dynamometric axis while adjusting the electronic parameter settings of the control system developed with company SEIA*. The ARTS Carnot Institute’s support combined with FIXATOR’s associated internal resources were decisive for marketing the system. Exolift is not only a technological breakthrough but also a QWL** strong determinant.
Exolift has received the regional Trophy for Innovation in 2014, before its marketing launch in 2015.
*A French-based SME specialised in industrial electronic repair
**Quality of working life
Ingénierie@Lyon helps introduce a new set of tools to improve brake pad manufacturing quality
Partnership Ingénierie@Lyon Carnot Institute - Renault and SMW AutoblokA piece of clamp jaw manufactured using direct metal additive processing increases existing machining productivity.
Ingénierie@Lyon helps introduce a new set of tools to improve brake pad manufacturing quality
Supporting Innovation
The clamp jaw placed over the chuck must be as light as possible to avoid strong clamping centrifugal forces during machining operations. Indeed, a heavier clamp would exacerbate tightening of the workpiece with induced deformations. IPC*, as part of Ingénierie@Lyon Carnot Institute, worked to make the holding clamp, manufactured by chuck specialist SMW AUTOBLOCK, lighter. The combined topological optimisation/metal additive processing has reduced the clamp weight by 50%, allowing for a reduced tightening. Therefore eliminating the risk of distorted brake discs during the machining process. Renault thus managed to improve process capability while ensuring quality of the brake pads
*IPC = Innovation, Plastic Technology, Composites
3D image of the optimised chuck/clamp piece (shaded areas represent cut-outs only possible using metal additive processing)
The client needs
Renault and SMW Autoblock have been faced with many obstacles in reducing the piece of clamp jaw, while maintaining its mechanical properties for a firm holding of the machined brakes. They subsequently turned to the IPC Technological Centre as part of the Ingénierie@Lyon Carnot institute. Using the OptiStruct structural analysis solver from Altair Hyperworks, the teams first re-examined design topological optimisation, so as to respond to the main requirements of improving mass and resistance constraints. The geometrically complex series part was subsequently produced using metal additive processing. The lighter clamp jaw is enabling to hold the machined part with better gripping conditions and a lower torque in comparable quality. As a result, Renault could increase productivity and reduce reject rates in production making allowance for improved ecological and economic balance.
Partnership
The Ingénierie@Lyon Carnot institute brings together both the IPC and 13 other reseach laboratories. The objective of its R&D spectrum is to develop new materials and technologies for applications in the field of transport, energy and health devices. In addition to multidisciplinarity the Institute’s research partnerships support innovation of very small companies and large international groups alike, .
The IPC Technological Centre, could dramatically contribute to Renault’s and chuck maker SMW Autoblock’s venture by combining two of its competences, i.e. topological optimisation and laser metal fusion. Such valuable work has been acknowledged and revered by the professionals. The project has been awarded the 3DPrint trophy for best applications for metal additive manufacturing in June 2017.
New MultiX X-ray spectrometer detects nitromethane from water
Partnership Leti Carnot Institute - MultiXThanks to Leti’s various skills, the combination of reduced stage security inspection process and travel safety is attracting both the airport authorities and other sector industries.
New MultiX X-ray spectrometer detects nitromethane from water
Supporting Innovation
How can we differentiate water from nitromethane in liquids? While conducting R&D to resolve such delicate matter, a Grenoble Isère-based business realised that it was able to concretely fulfil the issue of heightened security checks at airports. The use of the MultiX X scanner is becoming routine procedure to discriminate liquids in baggage. The main innovation rationale behind such technology is to fast-scan via efficient photodetection all screened photons rather than just a fraction passing through the scanned item. The detection sensor is an unparalleled source of information which has driven the American Authorities at US airports to use such technology to improve detection of explosives in hand-held baggage.
The client needs
MultiX has been utilising X-ray spectrometric detection technology since 2010 for non-destructive inspection and security screening to identify substances.
Their teams, widely dedicated to R&D, have given themselves the objectives of providing a reliable solution with reference to baggage screening that can be directly integrated to industry. To succeed in this increasingly competitive market, MultiX needed a partner capable of providing a major technological advance to offset the competition. The SME with 18 employees was able to develop in concert with Leti Carnot institute (Cea Tech) the entire workflow for processing X-ray spectrometry data. Such guarantee ensures detection of explosive compounds while making easier the traveler’s experience.
Partnership
The CEA LETI Carnot Institute has strived to maintain world-class imaging, notably health care radiography, expertise. The teams’ ability for spectrometric measurement of gamma- and X-ray using high quality sensors paired with information extraction algorithms have consequently been shared with their MultiX counterparts. Spurred on by Leti regarding their patent management, the SME has the competitive advantage to deal with faster development while creating jobs to support international business. The ME100 detector easily integrates into the clients’ scanning systems. Thus benefiting key security operators at sensitive locations or places with industrial activity.
At the heart of a winning strategy is collaborative robotics
Partnership ARTS Carnot Institute - KukaThe ARTS Carnot Institute helps Thyssenkrupp Presta France tostrengthen its production tool.
At the heart of a winning strategy is collaborative robotics
Supporting Innovation
By co-ordinating highly sensitive tasks both humans and robotic systems can perform very closely in order to bring improvements in both productivity and agility to the production teams. The on-site integration of LBR* iiwa, Kuka’s collaborative robot, into these OEM’s** highly automated production facilities is considered very innovative. Not only in terms of state-of-the-art technology but also regarding its contribution in relation to comfort at the workstation, new material architectures and process simplification. Beyond selecting the appropriate hardwares the real innovation revolves around the approach to setting an industrial policy for Industry 4.0 developed and tested based on multiple scenarios, while winning over the operators’ support) at the same time.
* Lightweight robot (Leichtbauroboter)
** Original equipment manufacturer
The client needs
Thyssenkrupp Presta France [attention, boutons des versions anglaise et allemande non actifs sur le site web de l’entreprise], which employs about 1200 people spread over 2 highly automated production facilities (Florange and Fameck), have been ensuring assembly of steering columns and EPS (Electric Power Steering) systems since 2001 and 2011 respectively. Praised by all the major car brands the company delivers on a just-in-time basis security components that can be found on nearly 1 car out of 7 around the world. To maintain and reinforce its position globally, the foundations for developing one’s production base remain insufficient. New solutions must be tried and tested constantly and the production teams driven to technical perfection regularly. Such endeavour could only be achieved through an influx of external resources with a long-term vision in line with the company’s values.
Partnership
With its strong network of 20 research labs spread over 15 production sites across 9 regions the ARTS Carnot Institute has the capacity to respond to a high volume of ad-hoc industrial inquiries quickly and efficiently and to provide decisive technological expertise at knocking down the technological barriers [OU unlocking the technological bolts]. In view of the appropriate Thyssenkrupp requirements, the ARTS Carnot Institute has developed a robust co-robot cell to assess the robot’s ability to perform specific rack ? assembly operations using different configurations and [steering ?] types. While affirming the need of a global vision, the ARTS Carnot Institute has provided impetus and supported Thyssenkrupp Presta France’s exemplary Industry 4.0 approach in the region to allow the business impact of collaborative robotics (ColRobot) to be encouraged, notably by the launch of a specialised Master’s Degree Programme at ENSAM Lille*.
*Arts et Métiers Paris Tech
Diota becomes the first French publisher of Augmented Reality software for industrial use
Partnership CEA LIST Carnot Institute - DiotaTechnological success for a recently launched start-up supported by the CEA LIST Carnot Institute.
Diota becomes the first French publisher of Augmented Reality software for industrial use
Supporting Innovation
Commercial success for Diota’s Augmented Reality (AR) software solution for the Manufacturing Industry is already under way. It offers above all new ways to get everyone acquainted with a new manufacturing, control and maintenance format. The primary asset of such leading-edge technology for CEA LIST: a model-based markerless 3D tracking device for object identification linked to a multi-criteria information overlay module. Second asset: a gateway connecting the software and Industrial Information Systems directly to each other.
The client needs
The DiotaPlayer solution enables the improvement of manufacturing efficiency through the interaction between the digital data interfaces and the workspaces. Diota’s AR software solutions empowers all human operators performing time-continuous operation tasks to simplify data collection using markerless technique while providing enhanced ergonomics. Via a link-up with the Corporate information system DiotaPlayer makes it possible for the operators to receive the 3D models created from the 3D scanned data at both plant and production line levels. Into the bargain, higher productivity gains and quality outcomes leading to a reduced number of resultant manual inspections.
Partnership
The CEA LIST research efforts are devoted to developing digital intelligent systems aiming to specifically meet the challenge of the Factory of the future. The teams as of 2009 have become involved in the project by supporting Diota’s start-up, also by bringing its expertise in the AR field. The fruitful partnership has given the start-up the opportunity to appeal to a vast number of large corporate groups but also SMBs using AR for communication purposes or to highlight their product portfolio. CEA LIST Carnot Institute, which collaborates closely with Diota, helps them continue writing their success story on a worldwide scale. With Safran and CEA Investissement’s entry in the stock of Diota, along with a doubling of the present level of its personnel, the start-up is stepping up its industrial development strategy.
