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Project Scope

Objectives

The overall project objectives include:

  1. Develop a prototype open architecture Smart Manufacturing (SM) Platform to facilitate extensive application of real-time sensor-driven data analytics, modeling and comprehensive performance metrics
  2. Accelerate the development, deployment, goal achievement and reuse of smart system applications while halving the cost
  3. Demonstrate SM Platform applicability, interoperability and operational security on two diverse commercial test beds at Praxair and General Dynamics. Employ new sensors, models and operating strategies to reduce waste heat.
  4. Develop plans to commercialize, sustain, and grow Smart Manufacturing technology through the SM Open Platform deployment services, accessible and composable application libraries (apps), alignment with provider involvement, and trusted brokering of data and applications in an industry defined Marketplace aligned with small, medium and large manufacturer requirements
  5. Demonstrate Project SM technology’s potential to make U.S. manufacturers more competitive and reduce annual carbon dioxide (CO2) emissions and waste heat. The project will begin at level TRL 4 and is expected to progress to TRL 6.

 

An Industry-Driven Approach

The Smart Manufacturing Platform will be built in parallel with the development of Smart Manufacturing System test beds for diverse applications. This approach will inform design concepts for Smart Manufacturing Platform development and create a push/pull commercialization strategy that accelerates its use in early adopter applications with significant measureable benefits.

The project will involve the use of two test beds—one in a steam methane reformer hydrogen production plant (Praxair), and the other in a forging/machining/ heat treating operation (General Dynamics). For each test bed, sensor-driven modeling, measurement, and simulation systems, in conjunction with the SM Platform, will be developed, deployed, and operated, allowing energy consumption to be managed in real time. An Energy Dashboard developed for each test bed will provide situation awareness by integrating the energy productivity metrics with real-time information. Previously unavailable intelligence will be used to identify overall operations improvement opportunities at both test beds. Finally, outreach programs will be created to disseminate the technology.

Brief Summary of Test Bed Demonstrations

  1. Praxair – Install image-based temperature measurements on Steam-methane reforming (SMR) unit so that real-time model-based decisions can reduce energy use and increase productivity in an SMR unit. SM Platform provides configurable, multi-vendor modeling and data management, provisions high performance computation and storage resources, and enables high fidelity modeling and interoperability with SMR controls
  2. General Dynamics – Install measurements and software for SM system to reduce energy use and increase productivity in machining of artillery shell casings and commercial metal parts. Deploy real-time data analytics and modeling to optimize heating and forging together with CNC machine operation – managing across the seams. Integrate energy and product performance metrics for an entire line operation.