Machine learning solution allows process optimisation and economic benefits

Netzsch Process Intelligence has created a smart manufacturing solution called sensXPERT, that allows process control in real-time. Via cloud computing and fully integrated mould sensors, data from different production lines, from everywhere in the world and from any device, can be evaluated and adjusted in real-time.

Processes in composites manufacturing are strictly predetermined and comparable to the extremely regulated standardisation in the manufacturing industry. On the other hand, legislative and public pressure with regards to sustainability goals such as material recycling, reduction of energy and scrap, and optimisation of production processes is steadily increasing. Those considerations were the starting point for two experts in materials science and sensor technology to develop a manufacturing control solution to allow the industry to detect deviations within the production process and to obtain concrete clues on how to adjust those.

JEC Composites Magazine discussed the challenges of the manufacturing industry with Dr. Alexander Chaloupka, Managing Director and CTO at sensXPERT, a brand of Netzsch Process Intelligence GmbH, and Ingo Schwarz, Managing Director, Schwarz Plastic Solutions GmbH, who started their collaboration two years ago. The result is sensXPERT, a data-driven smart manufacturing solution designed to improve productivity, cost and quality control. There are provable effects on sustainability with regards to dynamic cycle times, energy savings and scrap reduction.

JEC Composites Magazine: Could you demonstrate to our readers why predetermined processes are no longer acceptable?
Alexander Chaloupka: “Cost pressure is a growing issue. We experienced during Corona pandemic and the recent Ukraine war that moulders need more flexibility in material sourcing. To rely on one single material sheet for a longer production process is no longer standard practice in manufacturing. Too many parameters play a decisive role in maintaining the material quality, such as transport conditions, air pressure, temperature or humidity. A deviation from the standard may cause the process to get out of control. Our monitoring technology supports various production processes such as reactive injection moulding, resin transfer moulding, compression moulding and vacuum infusion, with a high focus on thermoset materials. We combine the domain knowledge of plant and processing technology with materials science to optimally steer the entire manufacturing process.”

What is the USP of your technology?
Alexander Chaloupka: “From a technological perspective, we offer a solution combining materials science and an in-mould material evaluation system that provides real-time answers. The know-how, complex and sophisticated sensor technology comes with broad domain knowledge. In addition to creating complete transparency in the manufacturing process of plastic parts, sensXPERT openly welcomes ecosystem partners who understand that stand-alone solutions will not be sufficient to meet tomorrow’s customer needs in addressing increasing production challenges.
We consider ourselves thought leaders and collaborators, true to the motto: Better together! In the long run, we all benefit from a more profound understanding between machine, process, and inline material behaviour, which becomes more measurable through collaborations.”

How does the interaction between sensXPERT and the customer work?
Alexander Chaloupka: “Once the decision to integrate the sensXPERT solution is made, the client’s tool makers can start to incorporate the sensors, which build the work foundation. The edge device acts as a real-time data evaluator and communicator and is close to the customer’s machine. The hardware installation is easily done, and the Corona pandemic was the stress test that even Australian customers like Carbon Revolution were served from afar without a hitch. The ongoing communication and part data evaluation lie in the hands of our data scientists and cloud experts. They are the specialists behind the always-on technology. sensXPERT continuously learns and retrains its machine learning models and AI. It is hand in hand work with our customer’s part production. The more parts produced, the more intelligent our technology gets, thus securing process stability and production efficiency. This was the case with Carbon Revolution, since they are producing large quantities of high-performance carbon wheels, tens of thousands per year in a highly automated production process. Carbon Revolution confirmed that they significantly progressed with our technology in their manufacturing process, since defective moulding processes can be detected at a very early stage, thus reducing the risk of quality losses.”

The sensXPERT technology was also selected as 2023 JEC Composites Innovation Awards Finalists in the category Digital, AI & Data.

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“The sensXPERT technology is designed for efficiency; so is our communication. Our customers operate worldwide and we can remotely serve them from anywhere. The client’s wish is our demand. The offered EaaS (Equipment as a Service) solution comes with various side services, such as characterising material properties, creating customised kinetic models, pre-installation consulting services, and providing economic data via profound ROI calculation, supporting the technological feasibility.”

What are the significant future challenges in manufacturing, and particularly for the plastics industry, and how does the sensXPERT technology cope with those?
Ingo Schwarz: “From a political point of view as far as the new regulations coming from Brussels are concerned and considering the public opinion towards plastics, we observe a growing pressure for the plastics industry. However, most plastics stakeholders still ignore the clear signals. Unfortunately, many topics and aspects get mixed up when…”

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