BoostUp! Europe 2023 Call

Talgo aims to create a virtual projection to indicate the drilling points’ location within the train with the required level of accuracy. The main challenge that Talgo faces is that once the coach structure is assembled, it is necessary to manually drill or mechanize certain areas of the structure complying with high precision standards. The location of such drills frequently is based relying on physical references taken from other relevant points within the structure. This leads to operations for locating precisely the points of drilling that are time-consuming and prone to fail. The potential solution should ideally be a projection system that is easy to install within the coach and able to reach high accuracy levels and is self-calibrated and self-adjustable to the different shapes and dimensions of the various coaches. As a result, it is expected that the solution should result in savings from using a single tooling system instead of several toolings, as well as in a reduction of the manufacturing time while keeping the same levels of accuracy.  

Automation of processes with a small batch size using robots is challenging due to the necessary high manual programming effort. That makes automation uneconomical. If the robot programming can be automated so that the specific coordinates on the component can be targeted without manual effort, this could be game changer for robot usage for many industry fields. voestalpine BÖHLER Aerospace wants to evaluate possible solutions for that challenge and to verify it on a specific use case: grinding of surface defects on forged components.  voestalpine BÖHLER Aerospace wants to automate the grinding process using an industrial robot for its forged components (parts appr. 0.02m – 3.5 m in size, weighting 10kg – 1250 kg). Due to the explained difficulties the grinding currently takes place by manual labor, where dozens of grinding operators grind out previously identified and marked surface defects. voestalpine BÖHLER Aerospace is looking for solutions that can automate the programming of the robot. Following workflow is suggested, as an example: 1) import of input files containing surface coordinates of each part and their identified – to be grinded – regions, (.stl, .iges), 2) Collision free path planning based on defect characteristics on part surface, 3) Consideration of all process limitations coming from grinding cell environment, 4) export calculated path, 5) Generate program for robot controller, 6) visualize result to the operator.

voestalpine BÖHLER Aerospace is looking for a solution provider, who can deliver this suggested workflow as an executable software running on our production equipment.

Volkswagen AG is looking for a solution provider for the energy optimization of factory buildings, especially with a focus on the optimization of fleets of mobile battery-powered vehicles and robots. On the basis of an expert study by an engineering firm from 2007 for their Dresden plant, potentials are to be derived as to which of the solutions rejected 2007 for economic reasons would be feasible today with new technologies. Based on these outcomes we want to take the next step to find current and viable solutions. The challenge aims to find a solution provider to run a professionally and scientifically (Fraunhofer) accompanied PoC project preferably with other Plants of Volkswagen Group.  

As an esteemed industry leader, Berg Propulsion is renowned for its manufacturing expertise in energy-efficient azimuth thrusters and controllable pitch propellers for marine vessels. With a steadfast commitment to energy efficiency, the company has carved out a prominent role in monitoring and controlling power consumption throughout the value chain of ship propulsion systems.  However, Berg Propulsion currently faces a challenge with their non-flexible on-ship security software configuration solution. The existing production process lacks adaptability, rendering it inadequate for meeting future needs. Consequently, Berg Propulsion is actively seeking a partner or supplier that offers existing solutions capable of being tailored to their specific production process. The sought-after solution should facilitate per-delivery configuration of security credentials and features, ensure robust data and system security, enable remote connectivity and management of credentials, and provide comprehensive software management, updates, and system recovery. It is imperative for the solution to seamlessly handle customized software during production while effectively storing and managing end-to-end security for remote connectivity. Scalability is also a key consideration, necessitating a solution or tool with platform-level capabilities to enable seamless connectivity across multiple products, data sources, manufacturing plants, ships, and services. Moreover, the solution should possess the capability to handle software updates, facilitate remote monitoring, and effectively manage data related to energy efficiency.

Dana Inc. is looking to implement an in-line automatic vision system to replace the current visual inspection on the axles, performed 100% visually by the operators. The main challenge that Dana Inc. faces is that it risks to ship the axles with wrongly assembled components, as a result of manual visual inspection. Dana Inc. has 5 axles assembly lines, and there is currently 1 person dedicated per line/ per shift to perform the visual inspection. In the past, Dana Inc. has tried installing cameras and scanner at the beginning of the paint line, but due to the axle swinging on the chain during towing, the system did not work properly. The main expectation is that the proposed solution  should be able to check the outer characteristics and customers’ interface of their axles, and the process will be completely automated.