Industry 4.0 Path of Digitalization - McMaster Faculty of ... · 1 DMG MORI Industry 4.0 Path of Digitalization. Industry 4.0 2 DMG MORI Industry 4.0 the 4th Industrial revolution

Industry 4.0DMG MORI1

Industry 4.0Path of Digitalization


Industry 4.0 the 4th Industrial revolution

End of 18th century Early 20th century Early 1970s Today

Com

plex

ity

1st industrial revolution: Introduction of the mechanical production with the help of steam power

2nd industrial revolution: Introduction of the mass production with the help of the conveyer belt and electrical energy

3nd industrial revolution: Automated production due to SPS and Robotics

4nd industrial revolution: Communication between factory machines for automatic process optimization

Industry 4.0What is industry 4.0


Industry 4.0


Industry 4.0Opportunities for engineering

Production Machine

http://www.emo-milano.com/en/home/





Industry 4.0@ our production plant


Design Department

Sourcing

Sales

Logistics

Warehouse

Production planning

Industry 4.0Shopfloor monitor – connected


Industry 4.0Shopfloor monitor – functions

Order Information› Bill of material (BOM)› Customer specific design details› Sales order› Missing parts› Technical documentsWorkflow› Electronical material call› Escalation management › Complaints management› Report of operationOperational acquisition› Working time› Down time› Additional timesStatus information› Order status› Order progress› Current operation


Industry 4.0CELOS - the I/F to the digital factory


Industry 4.0CELOS – Messenger APP


Industry 4.0PROCESS CHAIN

2. manufacturing 3. machining 4. service

› Job Manager

› Performance Monitor

› Condition Analyzer

› Technology Cycles

› Surface Analyzer

› Industry 4.0 package

› Service Agent

› Developer

› Update

1. preparation

› DMG MORI Process chain

› DMG MORI Virtual Machine



3. MACHINING

› Technology Cycles

› Surface Analyzer

› Industry 4.0 package

Selected examples

Ergonomics and time savings

Measurement cycles workpiece quality

Machining cycles technology integration

Monitoring cycles process reliability

Tool sort cycle 3D Quickset® Grinding 2.0 MPC 2.0 – Machine Protection Control®



4. MAINTENANCE

› Service Agent

› Developer

› Update Condition AnalyzerSignal green

Installation With documentation or video guided

Maintenance of customer

Delivery of goods

Condition AnalyzerSignal yellow

Service Agent Purchase, maintenance or DMG

MORI direct

Order e.g. at DMG MORI Service


Industry 4.0Condition Analyzer │Performance

DMC 80 FD Industry 4.0

APP Condition Analyzer Highlights

Platform for visualising, analysing and predicting machine statuses across all machines

› Data storage interfaceCentral storage (Cloud) of the status data

› Visually status diagnostics - Individual machine level (My Machine)- Factory level (All Machines)- Across all factories (All Factories)

› User dependent access rights Information and reports






Industry 4.0Condition Analyzer │Contents

DisplayMachine condition

Trend ofmeasurements

Process Monitoring› Direct monitoring and

controlling at the plant

› Short-term reactions when recognizing overloads

› Customization of machining operations

Analyse / certificationNC-programs

Optimizing / Quality check› Analyse and improvement

of machining operations

› Process certification /quality check

› Improvement of production and machine indicators

Integrated service videos

Guided maintenance› Integrated maintenance

videos for an easy independent maintenance

› Fast and easymachine maintenance

› Cost cutting

Increaseavailability› Recognizing machine

problems early and avoiding it

› Optimized exploitation and maintenance

› Target Information to maintenance


Industry 4.0Condition Analyzer │Contents

Display machinery condition

Increase availability

› Engine problems at an early stage detect

and avoid

› Optimized utilization and maintenance

› Targeted information on maintenance on

maintenance and repair


Industry 4.0Condition Analyzer

DMC 80 FD Industry 4.0

APP Condition Analyzer Highlights

Increase of the overall equipment effectiveness (OEE)Through recording, analyze and execute of machine data with direct feedback to customers and services

› Improved machine availability

› Projectable maintenance intervals and service costs

› Guides maintenance by service videos › guided machine






Industry 4.0Condition Analyzer │Sensors - milling

Coolant system

Spindle

Hydraulic

Ball screw drive

› Fluid level*› Temperature*› Pressure*› Filter contamination› Interval oil exchange*

* Already prepared

› Pretension› Temperature

Pneumatic

› Air pressure*› Air flow› Filter contamination

Control cabinet

› Fill level*› Temperature*› Filter pollution*

› Temperature*› Filter pollution*

› Temperature spindle bearing*› MPC: Machine protectioncontrol

Coolantaggregate

› Rest of the paper bandfilter*

› Pollution of the double switch filter*

› Coolant level*› Quality of coolant


Industry 4.0Condition Analyzer │Sensors - turning

* already prepared

Control of linear axes

Energy control Hydrauliccontrol

› Pressure, level› Temperature

Coolant lubricant management

› Pressure, flow rate› Filter check› coolant quality

Clamping control

› Torque, speed› Temperature

› Digital clamping pressure› Clamping position sensor

› Easy Tool Monitoring 2.0› Force, Speed› Temperature

› Energy consumption› Air consumption

HSP / GSPPneumatic

› Air pressure*› Air flow

› Fluid level*› Temperature*› Filter pollution*

Coolant aggregate


Industry 4.0Sensors: Spindle – MPC (i4.0)

Spindle - MPC Performance

Advantages

Representation in Condition Analyzer

› In Process vibration monitoring› Machine quick shutdown in case of a crash› Torque monitoring during drilling and threading

› Increased availability through:› Avoidance of drill breaks through

determination of tool wear› targeted maintenance due

to bearing condition diagnosis of spindle› Imbalance analysis for Tools

› Error analysis by visual display in Condition Analyzer (lights)

› Avoidance of machine interruption› Cost savings by reducing of damages in case

of a crash

Specific report to maintenance department

CondIt Io n AnAl y z e r

Sensor package milling i4.0

Function in Sensor package i4.0_ Process monitoring, certification,

optimize and analyze

_ Machine and tool protection

_ Spindle bearing diagnosis

MPC (Machine Protection Control)Preventive machine protectionby quick shutdown

SGS (Spindle Growth Sensor)Spindle displacement sensor for determin-ing and compensating the stem extensiondue to bearing kinematics and temperature

IKZ flow rate controlMeasuring the flow rate of the coolant sup-ply pump to ensure the required coolingcapacity and for certification of processesand components

Function in Sensor package i4.0Function in Sensor package i4.0_ Precision

_ Process optimize, analyzeand certification

_ Process monitoring, certificationand analyze

_ Machine and tool protection

Machine protection Accuracy Process safety

Industry 4.0

Customer benefits_ Energy an air consumption

(DIN5001, energy-audit)

_ Media control for preventivemaintenance (flow rate,level, lubrication condition)

Advanced sensor controlAdvanced sensor analysis

Temperature controlTemperature-analysis-system

MPCMachine Protection Control

Easy Tool Monitor 2.0Tool monitoring

Customer benefits_ relocation compensation

_ precision drilling;5 0 % toleranceutilization

_ Data-Logger fortemperature fingerprint

Customer benefits_ machine and

tool protection

_ diagnosis of thespindle bearing

_ Process monitoring

Customer benefits_ Tool breackage

and wear monitoring

_ process optimizationan analysis

State control Accuracy checkMachine protection Process monitoring

CondIt Io n AnAl y z e r

Sensor package Turning i4.0

Industry 4.0

_ Partner APPsIn 7 Schritten zur eigenen APP

_ Noch intuitiver

_ Neue Innovationen

10 new APPs – 50 new functions

Performance MonitorOEE /KPI Analysis at a glance

_ Partner APPs – In 7 steps to your own app_ More intuitive

dMg Mo r I Ce l o s

The platform of DMG MORI with new innovations

Industry 4.0


Industry 4.0Expansion stages of networking

MyMachine allMachine allFactory

Machine server

PC

Factory A Factory B

Smart Data

CELOS AppCondition Analyzer

Company server

Company server

Documents

Industry 4.0 Path of Digitalization - McMaster Faculty of ... · 1 DMG MORI Industry 4.0 Path of Digitalization. Industry 4.0 2 DMG MORI Industry 4.0 the 4th Industrial revolution