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Factories of the Future - The Italian Flagship Initiative

  • February 2019
DOI:10.1007/978-3-319-94358-9
  • Publisher: Springer, Cham
  • ISBN: 978-3-319-94357-2
Authors:
Tullio. Tolio at Politecnico di Milano
Tullio. Tolio
Giacomo Copani at Italian National Research Council
Giacomo Copani
Walter Terkaj at Italian National Research Council
Walter Terkaj
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Abstract

This book presents results relevant in the manufacturing research field, that are mainly aimed at closing the gap between the academic investigation and the industrial application, in collaboration with manufacturing companies. Several hardware and software prototypes represent the key outcome of the scientific contributions that can be grouped into five main areas, representing different perspectives of the factory domain:1) Evolutionary and reconfigurable factories to cope with dynamic production contexts characterized by evolving demand and technologies, products and processes. 2) Factories for sustainable production, asking for energy efficiency, low environmental impact products and processes, new de-production logics, sustainable logistics. 3) Factories for the People who need new kinds of interactions between production processes, machines, and human beings to offer a more comfortable and stimulating working environment. 4) Factories for customized products that will be more and more tailored to the final user’s needs and sold at cost-effective prices. 5) High performance factories to yield the due production while minimizing the inefficiencies caused by failures, management problems, maintenance. This books is primarily targeted to academic researchers and industrial practitioners in the manufacturing domain.
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Tullio Tolio •Giacomo Copani
Walter Terkaj
Editors
Factories of the Future
The Italian Flagship Initiative
Editors
Tullio Tolio
Director of the Italian Flagship Project
“Factories of the Future”, Direttore del
Progetto Bandiera “La Fabbrica del Futuro”
CNR - National Research Council of Italy
Rome, Italy
and
Dipartimento di Meccanica
Politecnico di Milano
Milan, Italy
Giacomo Copani
CNR-STIIMA, Istituto di Sistemi e
Tecnologie Industriali Intelligenti per il
Manifatturiero Avanzato
Milan, Italy
Walter Terkaj
CNR-STIIMA, Istituto di Sistemi e
Tecnologie Industriali Intelligenti per il
Manifatturiero Avanzato
Milan, Italy
ISBN 978-3-319-94357-2 ISBN 978-3-319-94358-9 (eBook)
https://doi.org/10.1007/978-3-319-94358-9
Library of Congress Control Number: 2018960237
©The Editor(s) (if applicable) and The Author(s) 2019. This book is an open access publication.
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Preface
Manufacturing plays a key role both in advanced economies and developing
countries because of the large contribution to the overall employment, value added,
gross domestic product (GDP) and social welfare. Manufacturing is also a pillar for
the tertiary sector, since manufacturing activities generate the need for services and
in turn manufacturing provides products and technologies for the operation of the
service sector. Furthermore, manufacturing is fundamental to guarantee national
independence and security and to design the future of our societies. Continuously
evolving grand challenges compel the manufacturing sector to innovate its pro-
cesses, technologies and business models to continue sustaining the national
economies and progress.
This book presents the philosophy and the findings of the Italian Flagship
Project Factories of the Future (La fabbrica del futuro 2012–2018). This flagship
project was a major national research program promoted by the Italian Ministry of
University, Innovation and Research (MIUR) and coordinated by the National
Research Council of Italy (CNR) to innovate the manufacturing sector and address
global challenges. Starting from an analysis of research policies, Chap. 1outlines
the main ongoing research programs and initiatives both at international and Italian
level. Among these initiatives, the Italian Flagship Project Factories of the Future is
presented in details. The roadmap for research and innovation implemented by the
flagship project is based on five research priorities that can be seen as different
views of the same factory of the future: Evolutionary and Reconfigurable Factory,
Sustainable Factory,Factory for the People,Factory for Customised and
Personalised Products,Advanced-Performance Factory.
On the basis of the five research priorities, the flagship project funded 18
research projects and 14 demonstrators. The findings of the specific scientific and
technological research projects and demonstrators are reported in Chaps. 2–19.
Chapter 20 proposes seven future missions resulting from the flagship project
that can be set ahead for the manufacturing industry. Missions are of vital impor-
tance to guarantee the evolution of our societies by means of new systemic solu-
tions. Missions will also foster the important role of manufacturing as a backbone
for the employment and wealth of our national and European economies. Indeed
v
missions such as Circular Economy,Rapid and Sustainable Industrialisation,
Robotic Assistant,Factories for Personalised Medicine,Internet of Actions,
Factories close to the People, and Turning Ideas into Products will have a relevant
societal impact and at the same time will require to address significant scientific and
technological challenges which will be particularly important in view of the next
strategic initiatives at national and European level, including Horizon Europe.
Moreover, the demonstration and exploitation of results related to missions require
proper research infrastructures. Therefore, Chap. 21 analyzes and gives examples of
different types of pilot plant together with a discussion about funding mechanisms
needed to support industrial research and make pilot plants sustainable.
Milan, Italy Tullio Tolio
Giacomo Copani
Walter Terkaj
vi Preface
Acknowledgements
The Director of the Italian Flagship Project Factories of the Future (La fabbrica del
futuro) gratefully thanks Prof. Francesco Jovane for his visionary approach to
manufacturing research that triggered the launch of the flagship project Factories
of the Future in the context of the National Research Plan (PNR 2011–2013). Many
thanks also to Prof. Quirico Semeraro and Prof. Vincenzo Nicolòfor the scientific
supervision and guidance of the activities of the two main streams of the flagship
project. A special appreciation goes to Dott.ssa Federica Rossi, Vice-director of
the flagship project. Finally, warm thanks to the present and past members of the
Implementation Support Group (ISG) of the Flagship Project Factories of the
Future: Walter Terkaj, Giacomo Copani, Eleonora Schiariti, Emanuela Alfieri,
Daniele Dalmiglio, Davide Ceresa, and Anna Valente.
vii
Contents
Part I Introduction
1 The Italian Flagship Project: Factories of the Future ........... 3
Walter Terkaj and Tullio Tolio
Part II Evolutionary and Reconfigurable Factory
2 Model Predictive Control Tools for Evolutionary Plants ......... 39
Andrea Cataldo, Ivan Cibrario Bertolotti and Riccardo Scattolini
3 Exploiting Modular Pallet Flexibility for Product and Process
Co-evolution Through Zero-Point Clamping Systems ........... 57
Marcello Urgo, Walter Terkaj, Franca Giannini, Stefania Pellegrinelli
and Stefano Borgo
4 Knowledge Based Modules for Adaptive Distributed
Control Systems ....................................... 83
Andrea Ballarino, Alessandro Brusaferri, Amedeo Cesta,
Guido Chizzoli, Ivan Cibrario Bertolotti, Luca Durante,
Andrea Orlandini, Riccardo Rasconi, Stefano Spinelli
and Adriano Valenzano
5 Highly Evolvable E-waste Recycling Technologies
and Systems .......................................... 109
Giacomo Copani, Nicoletta Picone, Marcello Colledani,
Monica Pepe and Alessandro Tasora
Part III Sustainable Factory
6 Innovative and Sustainable Production of Biopolymers ......... 131
Simona Ortelli, Anna Luisa Costa, Cristian Torri, Chiara Samorì,
Paola Galletti, Claudia Vineis, Alessio Varesano, Luca Bonura
and Giacomo Bianchi
ix
7 Integrated Technological Solutions for Zero Waste Recycling
of Printed Circuit Boards (PCBs) .......................... 149
Giacomo Copani, Marcello Colledani, Alessandro Brusaferri,
Antonio Pievatolo, Eugenio Amendola, Maurizio Avella
and Monica Fabrizio
Part IV Factory for the People
8 Systemic Approach for the Definition of a Safer Human-Robot
Interaction ........................................... 173
Alessandro Pecora, Luca Maiolo, Antonio Minotti,
Massimiliano Ruggeri, Luca Dariz, Matteo Giussani,
NiccolòIannacci, Loris Roveda, Nicola Pedrocchi
and Federico Vicentini
9 Haptic Teleoperation of UAV Equipped with Gamma-Ray
Spectrometer for Detection and Identification of Radio-Active
Materials in Industrial Plants ............................. 197
Jacopo Aleotti, Giorgio Micconi, Stefano Caselli, Giacomo Benassi,
Nicola Zambelli, Manuele Bettelli, Davide Calestani
and Andrea Zappettini
Part V Factory for Customised and Personalised Products
10 Proposing a Tool for Supply Chain Configuration:
An Application to Customised Production ................... 217
Laura Macchion, Irene Marchiori, Andrea Vinelli
and Rosanna Fornasiero
11 Hospital Factory for Manufacturing Customised, Patient-Specific
3D Anatomo-Functional Models and Prostheses ............... 233
Ettore Lanzarone, Stefania Marconi, Michele Conti,
Ferdinando Auricchio, Irene Fassi, Francesco Modica,
Claudia Pagano and Golboo Pourabdollahian
12 Polymer Nanostructuring by Two-Photon Absorption .......... 255
Tommaso Zandrini, Raffaella Suriano, Carmela De Marco,
Roberto Osellame, Stefano Turri and Francesca Bragheri
13 Use of Nanostructured Coating to Improve Heat Exchanger
Efficiency ............................................. 275
Antonino Bonanno, Mariarosa Raimondo and Michele Pinelli
x Contents
Part VI Advanced-Performance Factory
14 Surface Nano-structured Coating for Improved Performance
of Axial Piston Pumps ................................... 295
Antonino Bonanno, Mariarosa Raimondo and Stefano Zapperi
15 Monitoring Systems of an Electrospinning Plant
for the Production of Composite Nanofibers .................. 315
Luca Bonura, Giacomo Bianchi, Diego Omar Sanchez Ramirez,
Riccardo Andrea Carletto, Alessio Varesano, Claudia Vineis,
Cinzia Tonetti, Giorgio Mazzuchetti, Ettore Lanzarone,
Simona Ortelli, Anna Luisa Costa and Magda Blosi
16 Plastic Lab-on-Chip for the Optical Manipulation
of Single Cells ......................................... 339
Rebeca Martínez Vázquez, Gianluca Trotta, Annalisa Volpe,
Melania Paturzo, Francesco Modica, Vittorio Bianco, Sara Coppola,
Antonio Ancona, Pietro Ferraro, Irene Fassi and Roberto Osellame
17 CIGS-Based Flexible Solar Cells ........................... 365
Edmondo Gilioli, Cristiano Albonetti, Francesco Bissoli,
Matteo Bronzoni, Pasquale Ciccarelli, Stefano Rampino
and Roberto Verucchi
18 Mechano-Chemistry of Rock Materials for the Industrial
Production of New Geopolymeric Cements ................... 383
Piero Ciccioli, Donatella Capitani, Sabrina Gualtieri, Elena Soragni,
Girolamo Belardi, Paolo Plescia and Giorgio Contini
19 Silk Fibroin Based Technology for Industrial
Biomanufacturing ...................................... 409
Valentina Benfenati, Stefano Toffanin, Camilla Chieco,
Anna Sagnella, Nicola Di Virgilio, Tamara Posati, Greta Varchi,
Marco Natali, Giampiero Ruani, Michele Muccini, Federica Rossi
and Roberto Zamboni
Part VII Conclusions
20 Key Research Priorities for Factories of the Future—Part I:
Missions ............................................. 433
Tullio Tolio, Giacomo Copani and Walter Terkaj
21 Key Research Priorities for Factories of the Future—Part II:
Pilot Plants and Funding Mechanisms ...................... 475
Tullio Tolio, Giacomo Copani and Walter Terkaj
Contents xi
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