The Complete Picture -
Digitalisation in the Metal-working Industry
If you want to turn data into information, there are many major and minor parameters that need to be adjusted. These include consistency and unified languages. For a complete picture, 
it is also important for the maximum number of participants in the process chain to think and act digitally. As this article shows, AMB 2022 in Stuttgart will provide a platform for these solutions from 13 to 17 September 2022.
Decision-makers in manufacturing companies need a continuous overview of productivity and technical availability since these are still the key parameters. In addition, the metal-working industry is subject to challenges including sustainability and the shortage of skilled workers, with the latter demanding a creative approach. Digitalisation is said to help overcome these challenges, based on the motto "knowledge is power". With a growing number of sensors and smart programs, it is becoming possible to collect more and more data about machine tools. Once it has undergone further processing, this data can offer crucial information to help optimise processes.
DMG MORI has delivered some particularly impressive results, backed up by figures: One of the Group's digitalisation objectives is to be able to start up production faster using the digital twin. In this process, a virtual representation is made of every real machine tool at DMG MORI. Even before installation, this digital twin provides support when engineering production systems with flexible automation capabilities or when delivering training. It offers a dynamic representation of all components, functionalities and axes, as well as all NC and PLC control functions including the relevant cycles. This gives DMG MORI an increase in speed of up to 40% when starting up production. At the same time, costs are reduced by up to 30% and collisions are completely ruled out, which is extremely important to ensuring smooth and efficient operations.
Predictive Control of Systems
Figures like these give people the motivation to engage intensively with digitalisation and the development of new solutions for production and process optimisation. One such person is German Wankmiller, Chairman of the Board and CEO of
GROB-WERKE: "For mechanical engineering and plant construction, Industry 4.0 offers major opportunities and provides a basis for operating machinery and systems in a way that conserves resources while offering flexibility and productivity. This development is far from complete since it is an agile development process that is in a constant state of flux, with new technical changes arising on an almost weekly basis".
For Wankmiller, digital solutions have been a firm fixture in the industry for many years given the process of globalisation. In fact, he believes demand for the development of new and advanced solutions and products in the field of digitalisation will continue to rise in the coming years throughout the industry. He thinks the benefits are obvious: "In heterogeneous production environments in particular, automation and digitalisation concepts can significantly increase the efficiency of employees and systems. But it is also necessary to establish interfaces for networking these systems", says Wankmiller.
And he is taking an open approach to this task: In view of the further development of universal connectivity and more flexible adjustment options, the applications developed on a modular basis by GROB can be used to connect all types of machinery and controllers from all manufacturers - not just GROB - within GROB-NET4Industry in a comprehensive digitalisation platform. This allows users to analyse the performance of their machines and optimise processes. The company intends to showcase this at AMB, with GROB-NET4Industry integrated into all the machines that will be exhibited. Visitors will be able to experience first-hand the solutions offered by GROB for increasing transparency in production and manufacturing.
The modules within GROB-NET4Industry allow both the production and support areas relating to machining to be organised with the aim of ensuring optimal utilisation of the high-quality, high-precision machine tools. In combination with the user's enterprise resource planning system, the MES enables order management, planning and order control to be completed on the machines. From production planning, monitoring and analysis to visualisation of processes in workpiece processing, right through to proactive service and maintenance - every area of production is linked. GROB-NET4Industry products feature integration platforms for all machine types. The goal is to enable manufacturer-independent digitalisation concepts to be implemented and to offer all customers extensive project support.
German Wankmiller, Chairman of the Board and CEO of GROB-WERKE: "We already offer an attractive range of apps that allow our customers to monitor machines and implement various evaluations. This gives customers m
aximum transparency throughout their production process. There are also simulation options, solutions for unmanned operation and a comprehensive service and maintenance package".
Digital Twins for
Agile Production Systems
MAG IAS GmbH, a company in the FFG Group, has investigated the benefits of virtual commissioning using digital twins and its impact on projects. The results of the cost/benefit analysis of digital twins prior to introduction gave a clear picture. Moving or splitting the commissioning process does not lead to a reduction in the volume of working hours required. However, partially moving the commissioning process into the planning and procurement phase - in other words, in parallel with sections that determine the processing time - reduces commissioning and thus the project processing time. Through digitalisation of the commissioning process, functional tests can be repeated automatically at greater frequency even when no operator is present. The results of the investigation showed that detecting and fixing sporadic errors during virtual commissioning reduces the subsequent, unplanned expenditure required for troubleshooting after delivery. Experience with the digital process twin, which has been in use for several years, has demonstrated that an NC program with time and path optimisation can be put into operation without any risk of collisions.
The digital process twin in the MAG project is a workspace model that simulates the axis movements, the process-related non-productive times, the clamping device, the workpiece to be processed and the required cutting tools. Compared to PLC commissioning, the NC commissioning process is very short but offers clear benefits in terms of quality and time. This made it one of the motivations for developing the digital product twin for virtual commissioning. In the course of the quality and efficiency improvements in the engineering of complex machinery, the mechatronics approach has proven to be the best way to create components as mechanical, electrical and fluid-technology models in parallel, enabling a high level of standardisation to be achieved. In discussions at AMB 2022, users will be particularly interested in the findings relating to how individual the analyses need to be. After all, products are always created on a project-specific basis and are made up of individual mechatronics components: machinery, automation systems, workstations, measuring devices etc. The benefit is provided by the interaction between the three digital twins: process twin, product twin and production/system twin. Whenever production is moved a week earlier or the system ramp-up curve becomes steeper, users enjoy a higher turnover and a positive contribution is made to the overall result.
Image: R. Eberhard, messekompakt.com, BERHARD print & medien agentur gmbh
Source: Messe Stuttgart
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