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Through a number of case studies and design examples, this presentation will analyse what makes a good candidate for large format printing.
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Istituto Italiano di Tecnologia (Italian Institute of Technology) and the Camozzi Group have designed and built a robotic system, one of its kind in the world, to contribute to the safety of the new bridge in Genoa.
The robotic system will be verifying the integrity of the infrastructure using cameras and sensors and will allow operators to intervene with preventive maintenance actions through data processing algorithms.
Genoa, Brescia, 29 July 2020 - The construction and assembly of the robots, one of their kind in the world, which will be helping to make the Genoa San Giorgio Bridge safe, has been completed. The devices, designed by Istituto Italiano di Tecnologia (IIT) and built by the Camozzi Group, commissioned by the Temporary Association of Companies established by Seastema S.p.A. and Cetena S.p.A. (Fincantieri Group), will be contributing to the safety of the new bridge in Genoa regularly performing an automatic monitoring of the infrastructure by using cameras and sensors. The 4 robots - 2 Inspection Robots and 2 Washing Robots - will be operational next autumn, as soon as the installations servicing the system have been completed.
The robotic system is based on the installation of the 4 robots on the sides of the bridge: 2 of them will be in charge of inspecting the lower surface of the deck and processing the data in order to find any anomalies (Robot-Inspection) and the other 2 will be cleaning the wind barriers and solar panels (Robot-Wash). This robotic inspection system is the first automatic system in the world and provides a replicable model at the global level designed to enhance the safety of this type of infrastructure and of any civil works that may require automatic monitoring.
The 4 robots are made of carbon fibre structures, actuators and electronic components. In particular, the single-piece beams that will enable deck inspection have been made by transposing technologies that are typical of the aerospace and aeronautical industries and were built using 3D moulds created by the technology of the largest 3D printer in the world made by the Camozzi Group, the MasterprintTM machine.
The robots will be sliding over the bridge’s outer rails where they will allow operators to verify the infrastructure’s integrity sending the images and data acquired to a control room, thereby creating a digital database that, thanks to efficient analysis and prediction algorithms, will allow the operators to intervene with preventive maintenance actions, as required.
The robots, designed using IIT’s know-how in the field of industrial robotics, were built thanks to the ten-year experience of the Camozzi Group in production technologies and in the construction of sophisticated machinery employed in the aeronautical and aerospace industries. Success was achieved only due to the synergies created by the various enterprises involved in building a robotic system that is characterized by reduced weight, high structural stiffness to bear the sensors’ weight, low resistance to wind and good aesthetic quality. The robots will be operated from the control room via a Wi-Fi network. They are powered by batteries and charging stations have been spaced every 200 meters on the sides of the bridge.
Furthermore, in the event of adverse environmental conditions the robots are capable of interrupting operations and can safely reach their charging stations thanks to the anemometers and accelerometers with which they are equipped.
The system combines the strengths of automation in modern mechatronic mechanisms, an area where Camozzi has a considerable experience (especially in conjunction with industrial automation), with the autonomy of cognitive systems. In essence, an inspection system that uses completely independent “cognitive mechatronics”, which thanks to the four robots will be operating in addition to the control and maintenance activities already required by law. Moreover, thanks to its hardware and software versatility, the system can be implemented in the future with new technologies in such a way as to always be cutting edge.
The control system consists of two Robot Inspection and two Robot Wash which will be moving on the lower external parts of the bridge.
A Robot Inspection weighs over 2,200 kg and is equipped with 82 wheels used for moving along two axes and is over 7 meters wide. It is provided with a retractable arm for inspection consisting of a fixed part and a mobile part, both of which in carbon fibre. The arm has a reach of about 17 meters in total length so that it can touch the centre of the deck from the edge of the bridge. The external monitoring of the deck will be carried out precisely by means of the carbon fibre arm, which is capable of sliding along the entire length of the bridge retracting near the pylons; high-resolution cameras and sensors have been installed on it to measure surface conditions: i.e. paint deterioration, corrosion elements and state of the welds. The cameras will be transmitting images of the entire infrastructure in real time. Thanks to computational models, the data collected will be checked for the purpose of reporting any irregularities or anomalies.
A Robot-Wash weighs about 2,000 kg and has 56 wheels to distribute its load on the bridge edge; it is over 3.5 meters high, almost 8 meters long and is divided into two parts: one for cleaning and one for charging. The Washing Robot removes dust and other debris from the photovoltaic system and glass wind barriers, which demarcate the lanes thereby maintaining the infrastructure’s efficiency and functionality. One of the robot’s peculiar features is its sustainable use of water resources. The water used for washing the structures originates from rain and other condensation water collected from the same infrastructure. The Washing Robot is equipped with sensors that monitor both the transparency of the glass wind barriers and the amount of water found on the surfaces. These two parameters allow the robot to determine when to intervene in order to clean the surfaces. In case of water shortage due to droughts and periods of low humidity, the Washing Robot is provided with a blower for the removal of particulates thereby contributing to maintaining the infrastructure’s efficiency while waiting for the right amount of meteoric water to be used for a more thorough wash.
The two robots will be regularly travelling along the edge of the bridge via tracks and drive wheels along the entire length of the viaduct of approx. 1,100 meters, depending on weather conditions.
The Role of IIT
The project originated from an architectural proposal of the firm “Renzo Piano Building Workshop”, which Istituto Italiano di Tecnologia transposed and expanded in 2018 by designing a unique robotic system prototype, later developed industrially by Camozzi. IIT donated the project to the City of Genoa and created a team of pioneering companies for its implementation, including the Camozzi Group.
Partnership between the Camozzi Group and Istituto Italiano di Tecnologia (IIT)
The partnership with IIT started in June 2017 with the establishment of a Joint Lab, which initially focused on new materials and advanced robotics. The partnership has now expanded in several directions, the construction of the robots being one of the fruits of its progress.
SINTEF Ocean has been recently delivered a 6 meter long 3D printed ship model to be used for experiments in the ocean basin. Right now, this is the largest 3D-printed model in Norway.
"This is an experiment on our part" explains research leader Sigmund Kyrre Ås "in connection with the new Ocean Space Center, we are considering acquiring such a 3D printer ourselves, so that we can print models instead of building them manually".
Replaces PVC foam and wood
Today, the models are made of PVC foam and wood. PVC foam is a relatively soft material that is easy to process, modify and adapt. On 3D printed models, they are not as easy to change as they are made of hard plastic, but they are significantly cheaper and faster to produce. Production takes place in two stages; first, the plastic is deposited in several layers to form the geometry of the model. In the next step, the outer surface is milled down to the correct dimension and the model gets the surface finish.
We hope to be able to halve the production time by printing a model compared to today's method, which in turn gives a significant reduction in the number of working hours, Sigmund explains.
We are becoming more competitive
If we switch to using such models, we can become more competitive. The goal is to produce models with better accuracy, while reducing costs and production time. It may then be more appropriate to run more models per project, or make hull changes by printing over previous models. Streamlining model production will be important to utilize the capacity of the new sea basin and ocean laboratory planned in Ocean Space Centre.
The new model will soon be instrumented and tested in the towing tank, which will provide useful experience on how such models should be constructed. In addition, we will be better equipped to provide input to the supplier so that they can tailor a system that works well for model building. We will run drag tests of the model with different surface finishes, and compare with an identical model made of PVC foam and wood.
“Eyewitness News” interviewed Chip Storie – CEO of Ingersoll Machine Tools Inc - who expresses enthusiasm and satisfaction in taking part in the realization of the GMT, the revolutionary telescope to study the deep space.
Ingersoll Machine Tools has been selected among the most important groups at international level to make the precision steel structure that supports and maintains the GMT in position.
Chip Storie, interviewed in the video, recalls the importance of the experience gained in constructing the rotator for the most powerful solar telescope in the world, the Daniel K. Inouye (DKIST) installed in Hawaii.
The Camozzi Group company is producing and assembling the 1,300 tons precision steel mechanism that will support and keep in place the seven largest mirrors in the world that will follow the movement of celestial bodies.
The telescope will be placed at Las Campanas Observatory in the Atacama Desert, in Chile and will allow to overcome the current frontiers of astronomy.
The structure will be delivered by the end of 2025 in Chile and should be ready to house the mirrors in 2027.
For more information: FAQ GMT
A new initiative from Ferrari as part of the countermeasures against COVID-19. Designed in just five weeks, a reliable, versatile, easy to use and assemble ventilator, to optimise oxygen consumption. Produced using easily available materials at a lower cost than currently available pulmonary ventilators.
Maranello, 13 May 2020 - Scuderia Ferrari Mission Winnow and the Italian Institute of Technology have joined forces to come up with a pulmonary ventilator that can be used by hospitals as a vital tool when dealing with emergencies such as the current COVID-19 virus global pandemic.
The project goes by the codename FI5: the letters being the initials of the Maranello marque and the reseach institute based in Genoa, while the number indicates the number of weeks required to produce a fully functioning prototype, starting from a clean sheet of paper.
FI5 is just one in a series of initiatives set up by Ferrari and IIT. Over the past few weeks, the Maranello company has launched various corona virus health care projects, including direct financial support for the Modena area, as well as the production of valves for pulmonary respirators and fittings for protective masks, as well as the “Back on Track” programme, born out of the collaboration with a pool of virologists and experts, with the support of the Emilia Romagna area, with the aim of ensuring the safety of the company’s working environment, as from the moment production restarted last week.
How did the idea of FI5 come about? It began with a call from IIT, and a desire to make generally available to everyone going through this emergency in Italy and indeed in the rest of the world, not only the excellent production facilities and support for the many initiatives in the area put in place by Ferrari, but also the creativity, quick reaction times and know-how that are part of the DNA of a Formula 1 team like the Scuderia.
FI5 has been designed to meet the typical demands of medium intensive care; reliable, versatile, easy to use and assemble, able to optimise oxygen consumption and being produced in volume, using easily available materials, so as to have a far lower cost than currently available pulmonary ventilators. The technical specification of FI5, the drawings, the firmware, software and list of components are now available as an open source project, which means anyone can produce it. In fact, some Italian, Mexican and United States companies have already contacted Ferrari and IIT to move on to certifying and distributing the product. IIT, through connections to all European research centres, will put the project on the DIH-HERO network, used for robotic technologies in health care.
Involved in the project was the Scuderia working group, headed up by Simone Resta, Head of Chassis Engineering and Corrado Onorato, F1 Innovation Manager, with support from members of the Gestione Sportiva and the GT department, while IIT put together a research and engineering team coordinated by Marco Maggiali, Facility Coordinator Icub Tech and Andrea Pagnin, IIT’s research manager. Initially, they came up with a list of essential requirements, partly arrived at thanks to the experience gathered from various hospitals, including Milan’s Niguarda Hospital and the Policlinico San Martino Hospital in Genoa. The Camozzi Group also played a vital role in identifying some essential components, also experimenting with its own products in order to provide data useful for the simulation models.
There were five phases to the project, from design to simulation to the choice and supply of components to the production and testing of the prototype. The Scuderia’s engineers did the CAD design work, to define the pneumatic and mechanical parts and dynamic simulation. IIT sourced all the materials and designed the electronics, the firmware and the control software, also playing its part in the simulation, development and design of the wiring system and also made use of the Scuderia’s supply chain. All the work was carried out with a rigorous respect of the process logic, ensuring compliance with the necessary requirements in terms of safety and reliability, so that it could be effectively used in the field.
The first prototype was assembled last week at IIT headquarters in Genoa and underwent and sailed through all the functionality tests. Furthermore, analysis has already begun to see what further developments can be introduced. Just as in the world of Formula 1, those taking part in this unusual partnership between Scuderia Ferrari and IIT have never stopped thinking of ways to improve the product, be it a racing car or a pulmonary ventilator!
Mattia Binotto, Managing Director Gestione Sportiva and Team Principal Scuderia Ferrari Mission Winnow:
“The challenge of COVID-19 was one we wanted to take on. FI5 is the contribution we made as the Scuderia, fielding the very essence of what makes a Formula 1 team and more importantly, all the characteristics that make Ferrari special; its passion, its creativity and its desire to improve. This project was a very stimulating experience as well as being truly rewarding for all those involved, who worked side by side with our colleagues from IIT and the other partners. It is initiatives like these that make #essereFerrari, not just a slogan but a distinctive feature of our identity.”
Professor Giorgio Metta, Scientific Director of the Italian Institute of Technology:
“The technological transfer of research is one of the central elements of our strategy. There are several projects that are taking shape along these lines. However, what we have done with Ferrari goes further than that. It is a project initiated because of an urgent health emergency in our society to which we have responded very quickly thanks to the combination of the Scuderia that is the pride of our nation and famous around the world, and a research centre that is at the forefront of internationally respected scientific institutions. Spurred on by Ferrari’s practice of working at speed, we designed and built the prototype in just five weeks. FI5 is an example of the ingenuity, technology and determination which are an essential part of our procedures. But more than that, it shows that this is a country that works and wins. "
Dr. Antonello Forgione, Minimally Invasive Oncological General Surgery Niguarda Hospital:
"During the height of the Covid-19 emergency, faced with the need for ventilators, IIT came up with the idea of creating a portable device that could quickly made generally available. Within just a few hours, the IIT engineers brought Ferrari on board to set up an innovative project that would involve aspects of fluid dynamics, something at which the Maranello team excels. After five weeks, the result was the FI5, a device that can be used in hospitals around the world after undergoing any national certification requirements. We can deliver an innovative machine for use to the whole world free of charge. It is effective, advanced and performs well, while also being safe and durable. I would call it the first “Racing Ventilator.”
Lodovico Camozzi, president and CEO of the Camozzi group:
"We are proud to have been involved in this project with our staff and skills to design FI5, a truly wonderful story of collaboration and all-Italian innovation that gives us hope for the future."
The innovative assisted breathing device of MVM, born in Italy and developed thanks to a broad international scientific cooperation, has obtained the EUA (Emergency Use Authorization) certification of the Food and Drug Administration and can therefore enter the hospitals of the countries that recognise the US certification.
The rapid spread of CoViD-19 has dramatically predicted a possible shortage of ventilators with respect to the number of patients in many countries.
The innovative MVM device was born from an open access project to be easily and quickly produced anywhere at a low cost:
The creator of the project Cristiano Galbiati of GSSI, INFN and Princeton University explains: “MVM represents a paradigmatic case: on the one hand it shows the essential role that basic research has on society, and on the other it highlights the importance of an international and multidisciplinary cooperation to face great challenges. The EUA certification by the FDA is an important milestone: it has turned Milano Ventilatore Meccanico from a project into reality, which we hope will help to save many lives ".
The MVM project was born from the idea and initiative of some scientists involved in research on dark matter, with experiments at the INFN Laboratories of Gran Sasso, and in Canadian laboratories. The creation of sophisticated experimental equipment for research in fundamental physics has allowed the development of specific skills on complex control systems and for the management of gases, similar to those used in lung ventilators.
These experts have started the development of a first ventilator prototype at the technical service center dedicated to respirators of the company SAPIO Life in Vaprio d’Adda, near Bergamo, in cooperation with the Department of Physics of the State University of Milan.
But to bring the MVM ventilator to the patients, the contribution of scientists, clinicians, health professionals and some companies headed by Elemaster was essential:
Elemaster has made a team of more than 40 specialists and its laboratory available for the development of the first units and created the entire electronic part of the ventilator and subsequently presented the project to the FDA for certification.
After testing and qualifying processes of the performance of the first prototype with breathing simulators, it was possible to create the first industrialised prototype in a few weeks which proved correctness and feasibility of the conceptual design.
MVM is made up of pneumatic solenoid valves and not of mechanical switches. Its modular design adapts well to the exchange of components based on availability in different parts of the world. The design of the ventilator is of open access.
The final project will be published on arXiv.org and will be granted under license according to CERN OHL v2.0 by the Air Foundation.
The members of the MVM International Cooperation have undertaken this project using their own resources and have set up a crowdfunding campaign.
The INFN (National Institute for Nuclear Physics) coordinated the development of electronics. In a few days, the researchers designed the prototype of the board that houses the microcontroller and manages the solenoid valves, pressure and oxygen sensors and created the Graphic User Interface that allows to view the patient's vital parameters on an LCD display.
GSSI - Gran Sasso Science Institute participates in the project from the very beginning with Cristiano Galbiati, full professor of Physics of the GSSI and Prof. Fernando Ferroni, networking and communication facilitator with the scientific community on an international level.
The CNR National Research Council of Italy involved physicists and engineers from the Institute for Plasma Science and Technology (ISTP) and from the Institute of Intelligent Industrial Systems and Technologies for Advanced Manufacturing (STIIMA). The activity of the researchers mainly concerned the optimisation of the circuit and fluidic implementation (valves and regulators), sensors (of flow and pressure), intelligent control and support for clinical validation.
The University of Milano-Bicocca has involved not only its researchers, but also companies, research institutes, anesthesiology doctors of the San Gerardo Hospital in Monza who, thanks to their skills on lung ventilation and clinical experience with COVID-19 patients, were able to define and test the characteristics of the device.
The University of Milan La Statale has been involved since the beginning for the construction of mechanical parts for the first prototype. Currently researchers are involved to contribute in creating the user interface of the device and in preparing the technical documentation of the product.
The University of Bergamo, thanks to several different engineering skills, created and tested a technological solution of a high social impact with the aim of helping to respond quickly.
The University of Naples Federico II is one of the proponents of the MVM project with Giuliana Fiorillo, full professor at the Department of Physics 'Ettore Pancini', and member of the international coordination group that maintains contacts with all those who want to offer contributions as well as with researchers / companies of third countries who want to replicate the project.
The University of Pisa participates in the project to verify the absence of potentially harmful compounds released by the materials and components that make up the ventilator.
Collaboration has grown rapidly also internationally, including the CNL, TRIUMF, SNOLAB and the Mc Donald Institute, under guidance of the Nobel Prize winner Arthur McDonald of the Queen’s University from Canada, scientists of Fermilab, of the Princeton Plasma Physics Laboratory and different other universities from the United States. From Europe, researchers of the IN2P3 Institute of the CNRS in France have joined the project, as well as the CIEMAT laboratory in Spain and the National Centre for Nuclear Research in Poland and several other Institutes and Universities.
"We participated with great enthusiasm in the development of the MVM project," comments the Nobel Prize winner in Physics Arthur McDonald. "Personally, it has been an extraordinary experience to collaborate in an international team covering such a wide range of skills, working hard to help save human lives in this difficult time."
For more information
MVM Mechanical Ventilator Milano
Open source paper
to sustain the Camozzi Group’s growth
Brescia – 11 May - Crédit Agricole Italy and SACE united again to sustain the growth of Italian companies. In this operation, Crédit Agricole has granted a loan guaranteed by SACE intended to support the growth plans in Italy and the world of the Camozzi Group, Italian multinational leader in the production of components and systems for industrial automation but also present in the fields of special machine tools, spinning machines and processing of raw materials. The loan guaranteed by SACE - as part of its traditional operations for the benefit of export activities of Italian companies - has a total value of 40 million € over a period of 6 years and is aimed at supporting the Group's future investment plan related to both national and international growth.
The Camozzi Group is among the world leaders of the "Industry 4.0 revolution" with a production management model based on interconnecting physical and digital systems, complex analyses of big data that result in real time adaptation. The Group can also boast significant research projects regarding smart automation, energy efficiency and the use of innovative materials. “Crédit Agricole Italy is proud to be alongside companies of excellence like Camozzi, especially in this difficult period. We want to support the Italian entrepreneurial scene in a concrete way and be a partner of reference, not only financially speaking, and find new development opportunities together, offering consultancy and customised solutions” says Alessio Foletti, Head of the Corporate Banking Department of Crédit Agricole Italy.
Lodovico Camozzi, President and CEO of the Camozzi Group, said: "The attention of Crédit Agricole and SACE in supporting projects that are transforming the manufacturing sector at a global level has been consolidated over time and with today's operation they support our Group once again. We are investing with innovative products in important segments for the present and for the future of our society such as Life Science that, like never before with the current emergency, needs constant progress." “Through this operation, we confirm SACE's support to Italian companies of excellence such as Camozzi, that operate on the international market and make export one of their drivers of growth – said Simonetta Acri, Chief Mid Market Officer of SACE -. In such a difficult context in which SACE has been called to back all Italian companies, our intervention to support Camozzi's industrial plan strengthens the growth plans of a group that already boasts a strongly international footprint thanks to 18 production plants over the world and a distribution network in more than 70 countries"
Crédit Agricole Italy Profile
Crédit Agricole is present in Italy, its second domestic market, with about 14 thousand employees and more than 4.5 million customers for more than 77 billion of financing to the economy. The close collaboration between companies present in retail banking, consumer credit, corporate and investment banking, asset management and the insurance sector guarantees Crédit Agricole to operate in Italy with a wide and integrated offer, for the benefit of all economic players. Crédit Agricole Italy is present on the national territory with about 1100 points of sale, around 10,000 employees and more than 2 million customers. www.credit-agricole.it
Camozzi Group Profile
Founded in 1964, this Group is an Italian multinational and leader in the production of components and systems for industrial automation but also present in the fields of special machine tools, spinning machines and numerous other processes of raw material processing. Continuous research and technological development are the basis of the corporate strategy and the drivers guiding this strategy are linked to the constant creation of innovation for its customers, in a development process towards smart manufacturing. The Camozzi Group is present in 75 countries over the world with 30 subsidiaries, 2600 employees, 5 operating divisions and 18 production sites. www.camozzi.com
SACE is the Italian insurance-financial company specialised in supporting businesses and the national economic scene through a wide variety of tools and solutions to support competitiveness in Italy and worldwide. For over forty years, SACE has been the partner of reference for Italian companies that export and grow on foreign markets forming, together with SIMEST, the export and internationalization division. Furthermore, it cooperates with the banking system to facilitate, through its financial guarantees, companies' access to credit, with a role enhanced by the special measures provided for by the Liquidity Decree. With a portfolio of insured operations and guaranteed investments worth 134 billion €, SACE serves over 23 thousand companies, especially SMEs, supporting their growth in Italy and on approximately 200 foreign markets, with a diversified range of insurance and financial products and services.
Camozzi Machine Tools Division Ingersoll Machine Tools, Inc.
Camozzi Group Innse-Berardi S.p.A. Innse Milano S.p.A. Partner: PM Metalli, Somet
Camozzi Machine Tools Division Innse-Berardi S.p.A. Ingersoll Machine Tools, Inc.
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