industrie 4.0 area 2017 · IIoT, and Industrie 4.0“ Rüdiger Kügler,Wibu-Systems AG Lunch break...

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industrie 4.0 area 2017

| Das Kompetenznetzwerk der IndustrieIndustrie

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.2 | mav industrie 4.0 area September | 2017

Program

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Tuesday, September 19th, 2017

10:00 am – 10:30 am

10:30 am – 11:00 am

11:00 am – 11:30 am

11:30 am – 12:00 am

12:00 am – 01:00 pm

01:00 pm – 01:30 pm

01:30 pm – 02:00 pm

02:00 pm – 02:30 pm

02:30 pm – 03:00 pm

03:00 pm – 03:30 pm

Moderation: Armin Barnitzke,

Assistant Editor-in-Chief, Automationspraxis

„Joining Forces to Shape the Industrial Future

– Allianz Industrie 4.0 Baden-Württemberg“

Dr. Katharina Mattes,

Allianz Industrie 4.0 Baden-Württemberg

„Digital High Performance Production

from the German Cloud“

Johann Hofmann,

Maschinenfabrik Reinhausen GmbH

„Connected Machining – Digital Job

Management in the workshop“

Ines Schmid,

Dr. Johannes Heidenhain GmbH

„Manufacturing with intuitive apps“

Johannes Haar,

Soflex Fertigungssteuerungs-GmbH

Lunch break

„Industry 4.0 at the junction between

tool and machine“

Prof. Dr.- Ing. Michael F. Zäh,

TU Munich

„New Collaboration in the area of tool

management – CAD/CAM process for the

modern chipping process of tomorrow“

Christian Erlinger,

Coscom Computer GmbH

„X-Panel – Customized Industry 4.0“

Eberhard Beck, Stefan Großmann,

Index-Werke GmbH & Co. KG

„Smart Data Analytics: Productivity increase

of interlinked systems and automated

machine benchmarking“

Felix Georg Müller, Fraunhofer IPA

„Industry 4.0 communication with OPC UA“

Dr. Christian Mosch,

VDMA Forum Industrie 4.0

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Wednesday, September 20th, 2017

10:00 am – 10:30 am

10:30 am – 11:00 am

11:00 am – 11:30 am

11:30 am – 12:00 am

12:00 am – 01:00 pm

01:00 pm – 01:30 pm

01:30 pm – 02:00 pm

02:00 pm – 02:30 pm

02:30 pm – 03:00 pm

03:00 pm – 03:30 pm

Moderation: Armin Barnitzke,

Assistant Editor-in-Chief, Automationspraxis

„Distributed data access and edge computing

in productions plants”

Javier Diaz, Plethora IIoT / ETxe-tar Group

„More than industry 4.0 buzz words:

Information instead of data – Use of Axoom

IoT and Analytics at Felss“

Marc Detmers, Axoom GmbH,

Markus Preisinger, Felss Holding GmbH

„c-Com: an innovative approach to the data

management in the metal cutting industry“

Giari Fiorucci, c-Com GmbH

„Monetize your machines with modular

features – Licensing and Security in IoT,

IIoT, and Industrie 4.0“

Rüdiger Kügler, Wibu-Systems AG

Lunch break

„Intelligent components for machine tools“

Prof. Dr.-Ing. Jürgen Fleischer,

wbk Institute for Production Technology, Karlsruhe

Institute of Technology (KIT)

„Smart sawing – Highly efficient production

through innovative sawing technology“

Tim Mayer, Fraunhofer IPA

„Digital High Performance Production from

the German Cloud“

Johann Hofmann,

Maschinenfabrik Reinhausen GmbH

„Intelligent systems for machine tools –

Simulations and prototypes“

Prof. Petra Wiederkehr,

Virtual Machining, ISF, TU Dortmund,

Prof. Hans-Christian Möhring,

Institute for Machine Tools (IfW),

University of Stuttgart

„Process Monitoring based on drive data“

M.Sc. Chris Schöberlein,

Chemnitz University of Technology

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mav industrie 4.0 area | 3.September | 2017

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Thursday, September 21st, 2017

10:00 am – 10:30 am

10:30 am – 11:00 am

11:00 am – 11:30 am

11:30 am – 12:00 am

12:00 am – 01:00 pm

01:00 pm – 01:30 pm

01:30 pm – 02:00 pm

02:00 pm – 02:30 pm

02:30 pm – 03:00 pm

03:00 pm – 03:30 pm

Moderation: Frederick Rindle, Editor, mav

„Requirements of a digital engineering

process“

Tobias Wetz, Gühring KG

„From vision to practical application

of automation“

Tomas Hedenborg, Fastems Systems GmbH

„Real time data collection and analysis for

composite cutting in aerospace industry“

Julio Zurbitu, Fagor Automation

„Real time data from machine tools –

Monitoring and analysis with HeiTPM“

Christian Kurtz, Heitec AG

Lunch break

„Empirical individual machine data within the

data model for the energy sensitive planning

of cutting processes“

Dr. Volker Wittstock,

Chemnitz University of Technology

„Making turning machines digital: Perfectly

equipped for Industry 4.0 with TISIS“

Dennis Keim,

Tornos Technologies Deutschland GmbH

„From data to knowledge discovery in

machine tools”

Javier Diaz, Plethora IIoT / ETxe-tar Group

„Developing new business models”

Thomas Kinkeldei, VDMA Bayern

„Industry 4.0 Plug & Play – An open ecosystem

of partners. Competences, applications and

solutions to accelerate digitalization in the

machine tool industry”

Stefano Linari, Pier Luigi Zenevre, Alleantia Srl,

Maurizio Porta, Porta Solutions SpA,

Atonios Tsetsos, Advantech Europe B.V

Luigia Paccoia, Leonardo SpA

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Friday, September 22nd, 2017

10:00 am – 10:30 am

10:30 am – 11:00 am

11:00 am – 11:30 am

11:30 am – 12:00 am

12:00 am – 01:00 pm

01:00 pm – 01:30 pm

01:30 pm – 02:00 pm

02:00 pm – 02:30 pm

02:30 pm – 03:00 pm

Moderation: Holger Röhr, Editor-in-Chief, mav

„Feeling machine for Online Process

Monitoring and Control”

Benjamin Bergmann,

Institute of Production Engineering and Machine

Tools (IFW), Leibniz University Hannover

„Schiess GmbH – Change from classic

machine tool builder to a full-service-provider“

Bernd Duchstein, Schiess GmbH

„Potentials and Challenges of Wireless

Technologies for Production Technology“

Dipl.-Ing. Markus Obdenbusch,

Machine tool lab WZL of the RWTH Aachen

„Model-based development process for the

integrated planning of

cyber-physical production systems“

Chantall Sinnwell, Institute for manufacturing

technology and production systems (FBK),

University of Kaiserslautern

Lunch break

„FIELD – the open IoT platform of Fanuc“

Bernhard Lusch, Fanuc Deutschland GmbH

„High production processes, horizontal

integration and mass customization in

the metalworking industry“

Paolo Maifredi, Buffoli Automazione

Industriale – Electro Engineering

„Intelligent systems for machine tools –

Simulations and prototypes“

Prof. Petra Wiederkehr,

Virtual Machining, ISF, TU Dortmund,

Prof. Hans-Christian Möhring,

Institute for Machine Tools (IfW),

University of Stuttgart

„Industry 4.0 Plug & Play – An open ecosystem

of partners. Competences, applications and

solutions to accelerate digitalization in the

machine tool industry”

Stefano Linari, Pier Luigi Zenevre, Alleantia Srl,

Maurizio Porta, Porta Solutions SpA,

Atonios Tsetsos, Advantech Europe B.V

Luigia Paccoia, Leonardo SpA

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i d i 4 0industrie 4.0 area


industrie 4.0 area

PROMOTING COOPERATION

Networked, interlocked, connectedThe Allianz Industrie 4.0 is a network initiated and promoted by the Ministry of Economics in Baden-Württemberg. Together with part-ner organizations, we are bundling the competences of production, information and communication technology. Our goal is to accom -pany mid-sized companies as they head towards Industry 4.0.

Author: Dr. Katharina Mattes

Together with our network part-ners from companies, applied re-search installations, associations, chambers and social operators, we strive to establish Baden-Württem-berg as a globally leading region for Industry 4.0 technologies. Small and mid-sized companies play an important role in this pro-cess and are the focus of our work. Close networking of the participa-ting industry and technology areas is supposed to help them benefit from this alliance in a significant way. In order to achieve this goal, we use a comprehensive set of measures to support and streng-then the direct cooperation bet-ween all players.

Outfitter of the world

In addition to information offe-rings, there is a particular focus on networking the participating in-dustries and technology areas in focus. To do so, we can access the traditional strengths of our companies: As „factory outfitters of the world“, companies in Ba-den-Württemberg are already lead-ing in mechanical engineering and construction as well as in informa-tion and communication techni-ques geared towards the industry. Furthermore, our service offering encompasses – amongst other things – the ongoing competition „100 places for Industry 4.0 in Ba-den-Württemberg“. This is where we honor innovations that fully utilize the potential of Industry

4.0. We use these concrete exam-ples to show how new technologies are changing the worlds of pro-duction and labor, thus making di-gitalization tangible. Together with our partner organi-zations, we offer plant tours and company visits, where employees can see vivid examples of how In-dustry 4.0 is being used successfully and what options exist for imple-mentation in their own company.

Concrete applications

We support companies that are looking for a suitable entry into digitalization and concrete appli-cation cases from everyday busi-ness with our „Industry 4.0 Scou-ting“. This scouting is geared par-ticularly towards the needs of small and mid-sized companies.Our certified experts, who have experience with mid-sized com-panies, work together with ma-nagement and employees in a tar-geted manner to further develop the company-tailored solution portfolio. Thus customized con-cepts and measures are developed for successful implementation of digitalization projects. Compa-nies headquartered in Baden-Württemberg with no more than 500 employees receive subsidies of up to 50 % from the Ministry of Economics. ■

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Allianz Industrie 4.0 Baden-Württemberg www.i40-bw.de

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Dr. Katharina Mattes,

Allianz Industrie 4.0 Baden-Württemberg


industrie 4.0 area

ASSISTANCE SYSTEM WITH INTEGRATED DATA HUB AND PUMP

Digital High Performance Production from the German CloudThe experience report of Maschinenfabrik Reinhausen (MR) paints a picture of the fourth industrial revolution – proven in practical appli-cation and far away from any hype. It also answers the question of which digital competences employees need. Author: Johann Hofmann

The example of high performance manufacturing at Maschinenfabrik Reinhausen (MR) at the industrie 4.0 area shows the unavoidable complexity increase in production, its consequences and a possible so-lution to this challenge using the cloud. Pros and cons as well as se-curity insights are illustrated based on practical application. In his presentation, Johann Hof-mann links these topic areas to the fourth industrial revolution, whe-reas the term „Industry 4.0“ with its core elements of „Smart Facto-ry“ or „Internet of Things“ for example is illustrated.

Assistance from the cloud

In spite of all standardization ef-forts, e.g., using OPC/UA or MTConnect, the digitalization and networking of a machining pro-duction with a heterogeneous and historically grown machine park with widely different manufactu-rers and software versions resem-bles urban warfare. The cloud-ba-sed assistance system ValueFactu-ring offered by MR with integra-ted data hub and data pump puts you in a position to win this urban warfare.The presentation is directed at all those who are curious about the enormous development of production and ask themselves: „How can I change from being affected by Industry 4.0 to desig-ning it?“ You will find the answer to this question at the industrie 4.0 area. ■

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Maschinenfabrik Reinhausen GmbHwww.valuefacturing.com

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Digital competence of employees.

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Johann Hofmann, ValueFacturing


industrie 4.0 area

CONNECTED MACHINING BY HEIDENHAIN

Digital Job Management in the WorkshopWith the Connected Machining package of functions, Heidenhain supports the very individual networking of production with an all- digital order management while considering already existing IT infrastructures. The solutions of Connected Machining put the machine operator at the center of the workshop. Author: Ines Schmid

right at the machine. The operator can therefore prepare the pro-duction order in an efficient and paperless manner and set up the machine. Once the order is prepa-red, the machine operator digitally transfers all measurement data and quantities to the order ma-nagement system. The StateMonitor software gives the machine operator an overview of the current machine status di-rectly on the controls or a PC in the office, a smart phone or a tab-let. Furthermore, the StateMonitor software can actively send mes-sages, e.g., at the end of a pro-gram, if the machine stops, or in case of a service notification. The Heidenhain controls with the Connected Machining package of functions integrates flexibly into the process chain and helps opti-mize the knowledge transfer wit-hin the company. Connected Ma-chining allows for a uniform digi-tal order management in networ-ked production. You therefore be-nefit from:

∙ Easy use of data

∙ Time-saving processes

∙ Transparent processesIn the industry 4.0 area at EMO 2017, Heidenhain presents a pro-duction where all work steps from the CAD/CAM workplace to the finished part are networked. ■

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Dr. Johannes Heidenhain GmbHwww.heidenhain.de

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At the center of the com-

pany network: the TNC

user in the workshop.

Connected Machining by Heiden-hain integrates the machine tool into the IT infrastructure while putting the TNC user at the center of order management. Standard functions, options and hardware solutions of Connected Machining allow the user of the Heidenhain control system comfortable access to all information he needs for his work from across the whole com-pany network. At the same time, he can feed data from production back into the process chain so that

all those involved can work with the real data of the cur-rent order at all times. With the option #133 Remote Desktop Manager, the opera-tor can use ERP or CAD/CAM systems directly at the machi-ne. With the push of a single button at the TNC, the machi-ne operator accesses a Wind-ows PC. He gathers all rele-vant data for his production order from the company net-work and therefore saves time

spent wal-king between machine and office. Technical drawings, CAD data, NC programs, tool data, work in-structions, parts lists and ware-house informati-on are therefore available digitally


industrie 4.0 area SOFLEX

INTUITIVE OPERATION, UNIVERSAL USE AND REMOVAL AT ANY TIME

Manufacturing with intuitive appsIntelligent and digitally networked systems are supposed to make mostly self-organized production possible. People, machines, sys-tems, logistics and products communicate and cooperate with one another directly. Author: Johannes Haar

Networking is supposed to optimi-ze not just one production step, but the whole value chain. Addi-tionally, all phases of the product lifecycle are supposed to be docu-mented and made transparent – from idea to development, pro-duction, use and maintenance all the way to recycling. The digitalization of the producti-on processes all the way to active controlling of automated pro-duction systems is a cornerstone of Industry 4.0. Soflex offers a com-

prehensive product range begin-ning with the topics of detailed dy-namic planning and order control all the way to fully automated part and equipment provision. The control systems are easy to understand and use, and are mo-dular in their setup. Organization processes are shown in a transpa-rent manner and lead users to op-timal conclusion of their producti-

on processes. App-based function modules allow for expansion to the required levels that can be ad-justed to new or changing require-ments at any time. Soflex-CCS (Cell Control System) represents the latest generation of control systems that control and organize the automatic operation of flexible production systems. As a central interface within a flexi-

ble, automated production system, the Cell Control System takes over all tasks that ensure a highly pro-ductive operation. In addition to CCS, OCS (Order Control System) and MCS (Ma-chine Control System) round off the range of production products. OCS is geared towards the optimi-zation of the order flow at conven-tional, non-automated work pla-ces and machines. MCS controls the production processes of a stand-alone machine. The three control systems can be combined freely with one another. The advantages for the users are clear: Uniform operation, same in-terface, standardized organization processes, better machine utilizati-on and maximum flexibility. ■

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Soflex Fertigungssteuerungs-GmbH www.soflex.de

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Soflex control

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visualize pro-

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industrie 4.0 area

COMPONENT-SUITABLE MACHINE CONFIGURATION USING CYBER-PHYSICAL ADD-ON MODULES

Intelligent tools open up new potentialsUntil today, the interface between the intelligent tool and the control of the machine tool is created individually by the manufacturer. The research project „BaZMod“ has therefore looked for solutions that allow for a standardized exchange of data and energy between the tool and the production environment. Author: Prof. Dr.-Ing. Michael F. Zäh

On modern machine tools, intelli-gent tools are increasingly used to improve the workpiece quality and to extend the processing possibili-ties, e.g. measuring instruments, actuators, marking devices and tools that are equipped with sen-sors for process monitoring and optimization. All intelligent tools require power and communication interfaces to the machine tool control. These are now manufacturer-specific and must be individually installed and programmed in the machine soft-ware. The integration of intelligent tools is thereby restricted and the costs increase significantly. Stan-dardized interfaces and automatic-ally configuring systems, so-called Cyber-Physical Systems (CPS) are required to lift the innovation po-tential.

to automatic machine parametri-zation, this also includes the im-plementation of other additional functions. Examples of this may be break monitoring, automated tool feed control based on load, vibra-tion detection, deformation com-pensation as well as process-inte-grated roughness control. The physical interface for energy and data transmission as well as the software architecture is then deve-loped. This allows the data recor-ded by the tool to be used seam-lessly in the machine control. ■

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Institute for Machine Tools and Manufacturing Technology, TU Munichwww.iwb.mw.tum.de

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BaZMod spindle with inte-grated module for energy and data transfer.

Cross-manufacturer interfaces as a goal

The aim of the research project BaZMod is therefore to develop a cross-manufacturer interface bet-ween the rotating spindle and the control of the machine tool. This standardized interface integrates the mechanical and electrical coupling of the tool and provides the basis for bi-directional data exchange as well as energy trans-mission. A spindle with an integra-ted interface could be installed in the machine tool easily. But regu-lar spindles could also be equipped using an upgrade adapter.

First spindles are being used

The research project is divided in-to five work packages. First, the requirements for the interface we-re gathered. For this purpose, va-rious applications are examined in which an intelligent tool offers practical advantages. In addition


industrie 4.0 area

DATA IMPORT INTO THE TOOL MANAGEMENT SYSTEM

Rethinking the tool data process!In spite of DIN 4000 and ISO 13399, the exchange of data between tool management systems and operative CAD/CAM and simulation systems remains a big hurdle. Classical data interfaces restrict the agility of the operative IT target systems. Author: Christian Erlinger

Collaborative tool managementsystems are characterized by ahigh level of data integrity and da-ta quality. The clear goals of mo-dern machining processes to redu-ce change-over and positioning ti-mes at the machines make the sys-tem immensely important. In ma-ny realization approaches, it is stillapparent that the „data-distribu-ting“ administration system com-municates with the operative tar-get systems “one-to-one” via cus-tomized data interfaces.Especially in the area of tool graphics data for CAD/CAMand machine simulation systems, this harbors a great danger. Due tovery specific graphics prerequisi-tes, classical data interfaces lead toa target system specific data stora-ge of graphics information in thesystem. That means that the toolgraphics stored in the system aregeared explicitly to a specificCAD/CAM or machine simulationsystem.The process-technical one-waystreet is therefore already mani-

fested and prevents any change in the area of operative IT systems. Anew CAD/CAM or system for ma-chine simulation would lead to re-work of the complete data inven-tory in the tool management sys-tem.The introduction of standards is supposed to lead to a uniform de-finition of tool data. Many toolmanufacturers already provide tool data based on the respectivestandard. Graphic information isalso provided based on the stan-dards.However, practical application hasshown that CAD/CAM or machi-ne simulation systems require geo-metry data or graphics informati-on with various degrees of proces-sing. For example, it is apparentthat different graphics formats(STEP, STL, DXF), parametrizedcontour line descriptions in diffe-rent compositions, but also gra-phics information deviating fromthe initial information must beprovided for individual target sys-tems.

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Coscom Computer GmbHwww.coscom.de

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The TCI data platform allows for future-proof data storage in the tool manage-ment system.

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Practical application therefore shows that the existing standards are not sufficient, or that compre-hensive standardization appears rather unrealistic. Insurmountable problems ensue in project constel-lations where the software must communicate with different IT tar-get systems. Projects fail, project partners are frustrated and unne-cessary costs are created. Rethin-king is necessary!In addition to data administration, the tool management system must also assume a data processing task. It is necessary that the complete data pool is generated mostly automatically so that the administration system is set up future proof right from the first complete tool system. The necessa-ry in formation can then be provi-ded to the respective simulation system. ■


industrie 4.0 area

INDEX XPANEL I4.0 READY CONTROL SOLUTION FOR LATHES AND LATHE-MILLING CENTERS

The cockpit for tomorrow’s data trafficEmployees and machines in operative production very rarely have direct or networked access to the company’s IT infrastructure. This creates weak points and disproportional efforts when it comes to providing order-relevant information from different departments on site – at the right machine, at the right time, in the required currency and in the right context. Authors: Eberhard Beck, Stefan Großmann

With the Industry 4.0 solution cal-led „Xpanel i4.0 ready“ of the In-dex Group, the approach of a completely revised machine con-trol panel was implemented, which already integrates functions for comprehensive data exchange in its base version. Additionally, IT components can be added in a tar-geted manner so that every com-pany can easily implement a uni-versal information exchange bet-ween workshop level and higher-level company organization. These features ensure that the ap-plication spectrum of Xpanel ran-ges from simple but networked ex-change of order-specific data with drawings and documents to the complete and consistent integrati-on of individual company applica-

tions directly at the machine’s con-trols.And by the way, of course Xpanel also provides the user with famili-ar and comfortable setup and con-trolling of the machine…

Screen with two faces

From a technical point of view, the Xpanel solution for Index and Traub machines offers the possibi-lity to put „two views“ on the con-trol screen. The user can toggle quickly between the normal con-trol view and the second view at the push of a button. With this fea-ture, Xpanel already offers online user support with direct access to the complete user documentation or service information such as on-

line view of circuit or hydraulic diagrams or machine BOMs in its base version, even without neces-sarily requiring a network con-nection.But Xpanel really reveals its full strength with an additional indus-trial PC in the cabinet; then the user can use the second screen for running the 3D simulation of the virtual machine linked to the ma-chine in real time or create com-plex programs directly at the ma-chine via a CAM system – to name just a few of the possibilities. Of course the industrial PC called a VPC-Box can be used for com-pletely different applications as well, for example customer-speci-fic IT applications. To that end, Xpanel allows the IT department of the user complete access and management of the integrated VPC-Box – without any restricti-ons. This open system approach allows for unrestricted adaptation of the control application(s) to in-dividual user needs – anytime, now and in the future! This safe-guards your investments.There are (almost) no limits to In-dustry 4.0 data communication with Xpanel. ■

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Index-Werke GmbH & Co. KGwww.index-werke.de

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Together with an industrial PC (VPC-Box; op-tional) installed in the control cabinet, Xpanel offers additional possibilities of interest for the production pro-cess.


industrie 4.0 area

MORE PRODUCTIVE INTERLINKED SYSTEM – AUTOMATED MACHINE BENCHMARKING

„Making fast machines even faster“The „Smart System Optimization“ of the Fraunhofer IPA uses auto-mated benchmarking to bring all machines up to the highest possi-ble level. At the company Freudenberg Sealing Technologies (FST), this approach helped to reduce the cycle time by up to ten percent per machine. Author: Felix Georg Müller

In many production areas, dozens of identical machines carry out the same processing cycle all the time. According to the department of factory planning and production management at the Fraunhofer IPA, this is common for workpiece manufacturing in injection mol-ding, vacuum forming, or proces-sing of metal or plastics parts. Even though the machines have the same setup, some work slower than others. This is due to wear and tear of the components, vary-ing sensor behavior or different tool settings. However, companies can hardly see the reasons with the naked eye, because the machine cycles very quickly and undergoes many individual processes.

Data acquisition from within and without

Smart System Optimization makes it possible to conduct an automa-ted machine benchmarking and to bring all components to the best possible level. Key technologies are adapted algorithms that were developed specifically for the ana-lysis of quick-cycling bulk goods production lines. First, the overall process of the machine is defined and split up into individual pro-cesses, the sub-steps. Subsequently, the optimization tool is used to create a uniform data basis which is transferred to the analysis tool almost in real time. In order to col-lect data „from within“, a high-performing connector is used that accesses data from the machine

controls. Additionally, intelligent cameras are recording the relevant process features from the outside. Using this continuous data basis, the analysis tool immediately re-cognizes when a machine runs slo-wer than planned. The reason for the long process duration is also provided automatically. System manufacturers and operators can react immediately and make their fast machines even faster.

Successful application

The tool has already been used in a plant of Freudenberg Sealing Technologies for a number of complex injection molding machi-nes for sealing components. Over-all, the processing cycle per machi-ne was shortened by six to ten per-cent. In addition to machine benchmarking, smart system opti-mization can also be used to opti-mize fast-cycling fully-automatic production systems, where the tool automatically identifies errors and their reproduction throughout the process chain. At the EMO, the IPA experts are demonstrating Smart System Opti-mization using a mini-factory. ■

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Fraunhofer IPAwww.ipa.fraunhofer.de

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For the injection molding machines

at Freudenberg, the Fraunhofer IPA

was able to reduce the cycle time by

up to ten percent using Smart System

Optimization.


industrie 4.0 area

MAJOR BENEFIT FOR MACHINE BUILDING

Industry 4.0 Communication with OPC UA Machine building is at the heart of Industry 4.0, as it is both provider and user. One topic that is a prerequisite on the way to Industry 4.0 is the determination of uniform interfaces in production.

Author: Dr. Christian Mosch

Interfaces are defining the mecha-nisms of cooperation based on in-formation about products, pro-duction processes and their opera-ting materials. The manufacturer-neutral exchange of this informati-on leads to a new form of cross-company interoperability in pro-duction. The VDMA is pursuing the strate-gy of enabling its member compa-nies to approach Industry 4.0 in defined steps. A major step is the focus on the interface standard OPC UA. This is an open interface standard specified in the IEC 62541 series of standards; its ab-breviation stands for Open Plat-form Communications Unified Ar-chitecture.

The open Industry 4.0 interface standard

OPC UA is quickly establishing it-self for Industry 4.0 communicati-on amongst small and mid-sized companies in machine building and construction. The reason for this is that the companies can map their devices as well as the capabi-lity descriptions of their products in OPC UA.Device and capability descriptions are provided in defined specificati-ons, the so-called OPC UA Com-panion Specifications. A OPC UA Companion Specification is a cross-manufacturer information model which is the actual interface between components, machines and systems. With a concrete OPC UA Companion Specification, it is

therefore easier to integrate a new machine into a system, since stan-dardized device and capability in-formation is described identically at all manufacturers. Standardized device and capability information includes the description of the ma-nufacturer name, the device type, and the process data, such as for example temperatures, pressures, feed rates or cycle times.By using OPC UA Companion Specifications, companies in the machine building and construction business are pursuing clear goals: If the components, machines and systems will provide information about their own devices and capa-bilities independently and regard-less of manufacturer with the OPC UA Companion Specifications, ap-plication scenarios such as Plug & Work are within reach for pro-duction. Beyond Plug & Work, the field bus independent condition monitoring of components and machines and predictive mainten-ance can be derived as immediate benefits for the industry. ■

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VDMA Forum Industry 4.0industrie40.vdma.org

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Dr. Christian Mosch,

Forum Industry 4.0, VDMA


industrie 4.0 area

ADVANCED DATA ANALYSIS TECHNOLOGIES – FEATURING MACHINE LEARNING

Actionable insights towards competitivenessIndustry 4.0 opens new opportunities to make enterprises more competitive by applying advanced data analysis technologies, espe-cially featuring machine learning. Plethora IIoT aims to maximize your factory’s competitiveness, reducing downtimes, saving energy and planning production and maintenance in new ways, by perfor-ming machine learning-based knowledge discovery at the Edge.

Author: Javier Diaz

Plethora IIoT is a company that is part of Etxe-Tar industrial group,designing and developing cutting-edge answers for Industry 4.0.Being part of the Etxe-Tar Group and drawing from its ongoing feedback, bolstered by its long in-dustrial trajectory, gives us deeper knowledge of industrial enterpri-ses and their challenges. We are pioneers in the convergence OT and IT through the application of state-of-the art tools, such as ma-chine learning and high‐perfor-mance computing architectures.We boast an extensive background in industry, technology and data science, enabling us to see what ot-hers do not see, find what others do not find and understand what others do not understand.Plethora IIoT provides solutions aimed to equipment and manu-facturing process performance,real-time quality control, predicti-

ve maintenance, operational pro-cesses and consumption efficiency.Our solutions are built on a readi-ly available and fully trustworthy high-performance computing ar-chitecture, where real-time machi-ne learning algorithms are deploy-ed at the Edge. The architecture comprises multiple nodes which work at the edge, performing data acquisition, pre-processing and processing tasks. Nodes can com-municate data from different do-mains using OPC-UA or DDS-Se-cure industrial and other IIoT pro-tocols like TSN (Time Sensitive Network) for deterministic com-munications. At this level data noi-se filtering and sensor fusion are carried out to ensure data quality.In terms of data processing, speci-fically-tailored, Machine Learning algorithms are used to resolve a variety of relevant queries in gene-rating information useful for deci-

sion-making. These same nodes act as data gateways and commu-nicate with cloud platforms such as GE Predix, Microsoft Azure, PTC ThingWorx. Moreover, the master node plays a crucial role in this architecture to ensure excel-lent performance and deliver re-sponses in the required time frame. The master node takes ad-vantage of available resources in other nodes to perform high per-formance computing, while doing cluster management tasks, fielding queries and distributing jobs to every node deployed in the soluti-on.Plethora IIoT believes that compe-titive advantage is ensured by ge-nerating actionable insights about the production plant, whether in the production line, machines, components or workers. Therefo-re, solutions offered by Plethora IIoT under the paradigm Industry 4.0, provide a holistic view taking into consideration the convergence of machine-learning, software de-velopment and state-of-the-art hardware technologies for compe-titive advantage. ■

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Plethora IIoTwww.plethoraiiot.com

Image: Plethora


industrie 4.0 area

USE OF AXOOM IOT AND ANALYTICS AT FELSS

More than Industry 4.0 buzzwords: Information instead of data Big changes at the market for manufacturing companies require new holistic solutions that cover the whole value chain. Axoom is tackling this challenge and offers an open, digital platform for the industry. Authors: Wolfgang A. Haggenmüller, Felss Group and Dirk Thielker, Axoom Solutions

The machine and component ma-nufacturer Felss is actively driving the integration of Industry 4.0 into its metal forming processes. Through the Axoom Store, the company plans to offer smart ser-vices, e.g., for controlling of com-plex forming processes in tube ma-chining. For example, this includes an as-sistant for component and system design, a machine information sys-tem as well as assistance programs for maintenance, production opti-mization and energy saving. Ma-nufacturing companies can use such apps to expand their systems step by step. With the help of the smart services solutions offered by Felss, the cus-tomers receive data regarding the condition of their systems, allo-

wing users to produce even more efficiently in the future, increase quality and reduce the amount of scrap. By combining an app offering and an innovative IoT solution, Axoom takes the cooperation bet-ween machine manufacturers and end customers to a new level. With the platform and the new smart services, both productivity and quality in the companies are in-creased significantly.

Live presentation at the EMO

At the EMO, the processing of a component is presented as an ap-plication case using the new for-ming process Tube+ on the Felss Aximus machine. To that end, the

machine is connected live to the Axoom platform.The process data generated during the forming process, for example positions and forces, are registered at the Felss exhibition booth (hall 15, booth F105) in millisecond in-tervals and transmitted to the Axoom IoT platform via internet, where they are evaluated. The dashboard which shows the pro-cess data in a graphical representa-tion in real time will also be pre-sented both at the Axoom and the Felss booth. ■

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Axoom GmbHwww.axoom.com

Felss Group GmbH www.felss.com

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xoom

Felss Perfor-

mance Dash -

board for Smart

Services.


industrie 4.0 area

C-COM INCREASES EFFICIENCY ALONG THE WHOLE VALUE ADD CHAIN

Innovative data management for the machining industryThe machining industry is highly developed and works with state-of-the-art technologies. Complex machines and tools work together to ensure that components are processed safely within tight tolerances with maximum process stability. As modern as the processing is: the data management in the industry is often just as outdated.

Author: Giari Fiorucci

Often, printouts, hand-written no-tes and Excel files are still used. A lot of time is spent typing, sending, converting or searching for data. This has a significant influence on the efficiency of the whole value add chain. This is due to gaps in the data flow between all participants. One example for this is the handling of tools that are given to an external provider for regrinding: the provi-der receives a delivery with tools and often very little information. He enters these manually into his system and looks for the respective regrinding programs. The custo-mer receives an order confirmati-on which he uses to generate an order. He enters this order – again, manually – into his own system. When the reprocessed tools are

sent back to the customer, he notes in his system which tools were re-ground how many times. Therefo-re the same data is entered several times, leading to an unnecessarily high administrative effort. Another example is the process for acceptance of a machine tool, which usually starts with pre-ac-ceptance at the machine manu-facturer. There, the machine is tes-ted and achievement of the defined key performance indicators (KPIs) agreed upon with the customer is checked. Tools are set up, proces-sing parameters are adjusted, and the machine is set up.During this process, data is gene-rated that is collected in various Excel files or even on paper. The data is not stored in a central loca-tion. This in turn leads to immense problems when it comes to final acceptance, which takes place on the client’s premises. Neither the machine manufacturer nor the tool manufacturer can access changes during pre-acceptance in a structured manner. The pre-accep-tance process therefore often needs to be repeated. This extends the project duration, and the producti-on start is delayed.

Secure data in real time for all involved

In order to make these processes and the data handling more effi-cient, the c-Com GmbH has deve-loped the open Cloud platform c-Com based on the SAP Cloud

Platform. Due to the collaborative approach, clients and suppliers can work together using the same data. Data that already exists eit-her at the client or the supplier does not need to be copied or transferred again manually in a time-consuming process. It is visi-ble to all those involved in real time while ensuring maximum da-ta security. Different modules are available for the platform. With „Reconditio-ning Management“ and „Machine Run-Off“, for example, problems during tool handling for re-proces-sing and during machine acceptan-ce are eliminated through structu-red data that is available to all in-volved. Additionally, applications are available such as the native ap-plication „Tool Manager“. With this application, users of the plat-form can change data on mobile end devices, digitally document tool-related information, for example when a tool breaks, and share it in real time with their con-tacts. With these and numerous ot-her possibilities, c-Com creates the basis for a successful path to intel-ligent production. ■

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c-Com GmbHwww.c-com.net

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-Com

c-Com stands

for efficient data

management.


industrie 4.0 area

LICENSING AND SECURITY IN IOT, IIOT AND INDUSTRY 4.0

Sell your machine in slicesThe market for mechanical engineers and machine manufacturers has changed continuously over the past years. Price pressure due to globalization and requirements such as small production quantities present new challenges. If we look at the business models of recent years, four decisive models emerge. Author: Rüdiger Kügler

The basic business model is the sale of the machine or the device. Often, many years of engineering skills and brilliant ideas go into a new machine. Patents and legal steps are often not sufficient to prevent reproduction. Technical measures, for example protection against reverse engineering of the steadily increasing software share are indispensable for success at the market. Almost all machine manufacturers have realized that there is a big market for selling spare parts. The challenge is to recognize own parts and to not allow external spare parts, at least not during the war-ranty phase. Access to the machine should be limited to authorized and trained service personnel. The respective authorizations must be developed, recorded and renewed.

Sale of consumables

Print manufacturers have led the way; providers of dental grinding machines are using it as a matter of course. A large chunk of the profit is not made with machines any more, but with the consumab-les, for example printer cartridges or blanks. Machines are often sold at significant discounts in con-junction with a purchase agree-ment for consumables. The chal-lenge lies in the technical quality control. The fourth and innovative type of monetarization of machines is the subsequent sale of individual functions. Many machines and de-vices only differ in software-based functions. The hardware function is often identical for many, if not all product lines.

Licensing functions

With intelligent licensing, users can buy and use additional functi-ons or unlock them simply and within seconds. The manufacturer can streamline his product portfo-lio and offer low-cost entry mo-dels. This does not only have ad-vantages for him: anybody who ever bought a power drill knows what I am talking about. Wouldn’t it be nice to buy one mode for a low price and then be able to un-lock more torque at a later point when you need it? CodeMeter helps mechanical engi-neers with technical protection and licensing of software compo-nents, thus complicating replicati-on and offering the basis for unlo-cking of functions.Administration and delivery of li-censes and authorizations as well as quantity control are some of the basic functions of CodeMeter. ■

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Wibu-Systems AGwww.wibu.com

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Syst

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Monetarization

of production

machines.


industrie 4.0 area

MONITORING WEAR AND TEAR AND INCREASING PRODUCT LIFE

Intelligent feed axes with Industry 4.0 functionalityAt the wbk Institute for Production Technology at the Karlsruhe In-stitute for Technology (KIT), various Industry 4.0 solutions are being developed that promise a benefit in commissioning, operation and maintenance of machine tools through intelligent functionalities in the feed axis. Author: Prof. Dr.-Ing. Jürgen Fleischer

During initial commissioning and exchange of components, data re-garding the installed componentsmust be entered into the machine controls, often manually. This ma-nual effort can be reduced with di-gital transfer of the component da-ta. For this purpose, a methodolo-gy was developed in the BMBFproject Secure Plug-and-Work. A structured description in the openformat AutomationML is storeddirectly in the component andcommunicated digitally to the ma-chine controls. Within the machine controls, the transmitted data can then be used for example to auto-

matically create a compensationtable for pitch errors of a ballscrew.During machining, periodic exci-tations are created by process for-ces. If the frequency of this excita-tion is close to a resonance fre-quency, it results in undesirablechatter vibrations. This can beavoided by using a frequency-adaptable slide. In the slide consis-ting of carbon fiber reinforcedplastic (CFK), chambers can be fil-led with a fluid to alter the mass of the slide, so that mass and reso-nance frequency of the feed axiscan be adapted to the process in

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wbk Institute for ProductionTechnology, Karlsruhe Institute of Technology (KIT)www.wbk.kit.edu

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Networked Industry 4.0 functions of a feed axis.

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N t k d I d t 4 0 f ti f f d i

order to prevent chatter vibrati-ons.The ball screw that is often used to generate the translational feed mo-vement is also one of the compo-nents in tool machines that fails most frequently. At the wbk, pro-cesses are developed to monitor wear and tear and increase pro-duct life, as the current industry practice shows a trend towards over-lubrication which reduces the maximum possible component li-fe. The process for adaptive lubri-cation of ball screws developed at the wbk compares existing actual figures of frictional torque and temperature with the model-ba-sed, ideal target values. If the tar-get threshold is exceeded, additio-nal lubrication can be triggered as needed and the life of the compo-nent can be extended. The solutions presented by the wbk are networked with commer-cially available solutions of Bosch Rexroth AG via the open commu-nication standard OPC UA. Net-working via OPC UA allows for cross-manufacturer communica -tion and thus central information merging on various end devices. ■


industrie 4.0 area

CYBER-PHYSICAL SYSTEM FOR SELF-OPTIMIZATION OF MACHINING PROCESSES

Intelligent tools, fixture systems and process controlsThe Institute of Machining Technology (ISF) of the Technical University Dortmund and the Institute of Manufacturing Technology and Quality Ma-nagement (IFQ) of the Otto-von-Guericke University Magdeburg worked together in several European network projects to develop and research sensor- and actor-integrated workpiece clamping systems as well as sen-sory tools and process control strategies.

Authors: Prof. P. Wiederkehr (ISF) and Prof. H.-C. Möhring (IfW)

When machining thin-walled workpieces, different effects may manifest that can lead to a bad processing result or even result in scrap. Structural components like they are installed or used in air-planes in particular are prone to distortion due to internal stress which only becomes visible after processing once the workpiece is unclamped. Furthermore, critical component vibrations may occur that can lead to bad surface quali-ty, especially when machining thin-walled elements such as im-pellers or blisks.

The EU project INTEFIX tackled these challenges. Within the frame-work of the project, an adaptive fixture frame was developed that uses intelligent sensors and actors to identify and compensate for component distortions during pro-cessing. With the help of the intel-ligent device, the processing time for an aviation reference compo-nent was shortened by more than 20%. Additionally, a fixture sys-tem was developed that can be used to identify critical component vibrations during the process and reduce them using active counter-

vibrations. By using a proprietary process simulation system, the dynamic behavior of tool, work-piece, clamping system and machi-ne could be predicted for various stages of processing and conside-red in the system’s layout.

Preventive process regulation

During another cooperation pro-ject, preventive process regulation strategies for mold construction based on a sensor-integrated ma-chining tool and using process simulation were analyzed. Using the sensory tool, vibrations can be registered during the ongoing pro-cess, while process instabilities can be predicted using the process simulation. Based on the combina-tion of simulation and sensors, a concept for adaptive process regulation was developed in which the predicted process states are considered and the simulation is used as an additional source of information. ■

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Virtual Machining, ISF, TU Dortmund, www.isf.de

Institute of Manufacturing Technology and Quality Manage-ment (IFQ), Otto-von-Guericke University Magedeburgwww.ifq.ovgu.de

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Intelligent device

for reduction

of component

vibrations.

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Sensory machine tool.


industrie 4.0 area

INNOVATIVE IDENTIFICATION AND MONITORING ALGORITHMS AT FIELD LEVEL

Process monitoring begins with the drive

In this context, the machine-inter-nal control and drive systems in particular constitute a major im-provement lever. Current research projects of the Technical Universi-ty Chemnitz are addressing the in-tegration of innovative identifica-tion and monitoring algorithms di-rectly into the drive-internal con-trol units, thus shifting the intelli-gence from the process control le-vel to the field level. First of all, the basis is proper commissioning of all drive control loops. This currently requires a high degree of time and expertise,based on partially non-transparent control mechanisms and adjust-ment standards and only permits little influence on the results.

By using a new type of commissio-ning methodology using simulati-on-based optimization, the timerequired for commissioning can bereduced significantly. In additionto automatic modeling of the me-chanical process behavior, the pro-cess is characterized by a high levelof transparency, which also showsin the contribution of userknowledge by defining freely se-lectable auxiliary conditions.Furthermore, systems currentlyavailable at the market have thedecisive disadvantage that the pa-rameterization of the drive controlremains mostly untouched aftercommissioning, even though thefeed axis is subject to different in-fluencing variables over time (e.g.,

friction, inertia) that have a direct influence on control behavior. This is due to the fact that the evaluati-on of the control quality can only be subjective and requires experti-se, and options for continuous mo-nitoring are missing. This deficit is offset by compres-sing drive-information into a sca-lable value based on so-called per-formance indices. In combination with the process-supporting ap-proach for parameter identificati-on and vibration detection, they form the basis of online-capable adaptation of control parameters,thus enabling intelligent and self-regulating adjustment of the feed drives.The goal for the future is to link this data available within the drive with suitable models to gain directinformation about the current pro-duction process, thus further pro-moting the substitution of additio-nal sensors. ■

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Institute for Machine Tools andProduction Processes (IWP), Chemnitz University of Technologywww.tu-chemnitz.de/mb/ WerkzMasch

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Monitoring and adaptation of drive controls.

Faced with smaller lot sizes and increasing raw material prices, the-re is a rising demand in the area of machine tools for self-monito-ring and self-regulating systems in order to be able to meet the de-mand for intelligent and autonomous production systems in the sen-se of Industry 4.0. Author: Chris Schöberlein


industrie 4.0 area

IMPROVE AND CONNECT INTERNAL PROCESSES AND COMMUNICATION

Requirements of a digital engineering processDigital engineering processes calls for high demands for data ex-change between user and tool manufacturer. Up to date and always available data as well as data integrity and compatibility with availa-ble standard Tool-Data-Management Systems belong to the most important requirements to ensure process secure integration into customer processes. Author: Tobias Wetz

In spite of the high effort to supply and adapt current process structu-res there will be chances for both, user and tool manufacturers, to improve internal processes and communication relations between customer and suppliers. To mini-mize risks, and maximize process applications, unified standards that, for example, define the level of detail of 3D tool models and de-fine the cut and no-cut areas of the tool, are a necessity.Thanks to intensive work with tool manufacturers, users and sys-tem suppliers, we succeeded to standardize the data exchange bet-ween customer and Tool manu-

enable the automatic loading of Exchange Data into a Tool Ma-nagement System (TDM).

Line DIN4003:Concept of structure of 3D-Mo-dels based on attributes referring to DIN4000.Describes the representation and the structure of a three dimensio-nal CAD-Model which meets the requirements and Specifications for a digital Engineering process. (Coloring for CUT/NOCUT areas, cutting lines and coordinate sys-tems for automatic software based assembly)

DIN69874–2 graphical represen-tation — Part 2: Layer assignment for operation material graphics.Describes the two dimensional re-presentation for the data exchange between tool manufacturer and user. The composition, defined in regard of contents and graphical display, uses a predefined layer structure.

DIN69874–3 Graphical data re-presentation — creation of docu-mentation for standardized data exchange — Part 3: Definition of the title block cha-racteristics and the referring XML data exchange.Describes and defines the data, used for automatically created do-cumentation. ■

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Gühring KGwww.guehring.de

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Graphical data

display referring

to DIN69874-2.

facturer in the area of 2D graphics and 3D models as well as the ne-cessary object parameters.To ensure the data integrity there are several tools especially desig-ned for test and validation purpo-ses.

Data Exchange Standards:

DIN4000–102 object parameter lists Part 102: Data Exchange for Object Para-meter list by XML Schema.Describes the Data Exchange of classifiable Object Parameters, with help of an XML-Structure, to


industrie 4.0 area

LOOKING AHEAD TO THE DIGITAL FUTURE

Automation from vision to practical applicationDigitalization is an irreversible process that is already introducing lasting changes to the manufacturing industry today; but it’s not just the already existing technologies that are driving the digital transfor-mation, but most of all the strategy. Author: Martinus Menne

The ability to follow this trend re-quires a clear strategy on behalf of management. In this case, it means to change the corporate culture to promote and support realignment. The current degree of maturity of digitalization in Germany is alrea-dy fairly advanced. This is a wel-come development that should be supported with targeted measures. For Fastems, a provider of soluti-ons for automated part and palette handling, the topic of digitalizati-on in itself is nothing new, since the company has been developing the software for its automation so-lutions in-house for more than 30 years. If we look at the known path of introduction and effect of digitalization or the industrial in-ternet with its short-term and long-term goals, we see that Fas-tems has already achieved the se-cond level and therefore the end phase of goals that can be imple-mented short term by introducing new products and services.The best examples for this are the Manufacturing Management Soft-ware (MMS) for predictive plan-ning and detailed controlling of automated production processes, and a remote service that can be used to already fix 85 percent of all problems at the client today without requiring a service techni-cian on site. „The next step will be to use predictive maintenance and data analytics to avoid at least 80 percent of all potential problems in production before they even ap-pear,“ explains Tomas Hedenborg, CEO of the Fastems Group.

Fastems sees its role in service to its clients, and – amongst other things – in improving competitive-ness through automation, provi-ding attractive working conditions for the future, opening up new va-lue add potentials through the use of groundbreaking technologies and enabling real process innovati-ons while using robotics at all le-vels of the production value chain. Beyond that, however, the compa-ny also wants to create new oppor-tunities through radical change concerning how productive soluti-ons can be delivered, installed and used supported by software and the industrial internet.As a pioneer in digitalization, Fas-tems already started to change its company culture. „Already several years ago, we started to change

our structures, prepare our em-ployees’ mindset for the new age of digitalization and introduce agi-le methods from the area of soft-ware for the development of our products,” said Hedenborg. Other prominent examples from the so-lution portfolio that will be pre-sented by the Group CEO during the EMO speak for themselves against this background. ■

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Fastems Systems GmbHwww.fastems.de

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The Manufactu-ring Manage-ment Software (MMS) automa-tically plans production ba-sed on the cur-rent order and production si-tuation and all required resour-ces – and pre-dictively too!


industrie 4.0 area

MACHINING OF COMPOSITE MATERIALS IN THE AEROSPACE INDUSTRY

Collection and analysis of real-time dataIn aerospace industry precision, productivity, high-strength and lightweight are of utmost importance. In order to achieve these re-quirements of precision and productivity, it is essential to integrate the most advanced control systems and different sensors into the machines. Author: Julio Zurbitu

The presentation will show some of the systems that the machine tool manufacturers have integra-ted with Fagor Automation con-trols to respond to the specific needs of their manufacturing pro-cesses.Initially it will be presented the tools that manufactures have at their disposal to design and imple-ment advanced strategies of con-trol that allow them to design in-telligent machines that adapt to the conditions of operation.

Practical examples

The first application case that will be presented will deal with the dif-ferent temperature gradients in the manufacturing process that af-fected the accuracy of the machine and implied to reprocess the parts. In this case the manufacturer solu-tion was to integrate different tem-

perature sensors in strategic locati-ons of both the machine structure and the workpiece, and then with a mathematical model of the ther-mal expansion of the machine, it was possible to compensate in real time the displacements of the 5 axes involved in the machining and increase the precision.The second case that will be pre-sented will be, how to increase the accuracy of the pieces produced, taking into account the structural deformations due to the high acce-lerations achieved in the cutting processes. In this case, the accele-ration of the programmed path and a model of the behavior of the structure of the machine were used to estimate the deformations of the structure of each axis. With this estimation, the movement of each axis were compensated in real time, reaching the required precisions with high accelerations.

Modifying the force in real time

The third case deals with friction stir welding for making high-strength, fatigue and fracture resis-tant welds. In this case, a force sensor is added, which together with the speed of rotation, feed ra-te and a process model allow to optimize the welding process by modifying in real time the force. In all cases shown in the presenta-tion, an 8065 Power CNC from Fagor Automation has been used thanks to the option to integrate third-party algorithms, real-time reading, execute and compensate the axes movements. ■

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Fagor Automation www.fagorautomation.de

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With the help of

Fagor Automa -

tion controls,

intelligent

machines can

be built.


industrie 4.0 area

MONITORING AND ANALYSIS WITH HEITPM

Real-time data from the machine tool When Industry 4.0 came along, the strict allocation of production systems and products was replaced by flexible, networked producti-on systems. The intelligent networking implemented by Heitec in the machine tool area, their connection to ERP systems and integration into the management level constitute the next step of integration.

Author: Christian Kurtz

Creating transparency means mo-nitoring systems and their pro-duction statistics directly from the machine (i.e., without detours, ba-sed on the SSOT process) to al-ways have an overview of availa-ble production capacities and, if applicable, remaining run times of

maintenance and repair assistant and a broad, suitable solution portfolio for individual increase of system safety.

Transparent integrated production processes

Production data and machine data can also be linked seamlessly with commercial processes, synchroni-zed and integrated directly into the commercial applications of the ERP systems. State-of-the-art SAP technologies and the HEISAB process compe-tence are used for integration.Additionally, the surface technolo-

gy SAP Fiori provides easy operati-on, attractive design and device in-dependence through the launch pad with mobile use for quick and low-cost entry into a mobile IT strategy.

The following solutions can be implemented for production management:

∙ Event-controlled inte-gration with SAP ERP and the respective master data (work plans, bills of material, etc.)

∙ Graphical supplemen-tation of work plans with detailed processes such as rework or repair loops

∙ Administration and flexible allocation of gra-phical work and test in-structions for products, processes, and work pla-ces to the respective work place

∙ Workpiece carrier and container management

∙ Production and main-tenance calendar for ma-chines, systems, tools,

measuring and testing equipment

∙ Integrated documentation of operations, quality, and personnel timekeeping data

∙ Configurable worker dialogues for touchscreen terminals ■

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Heitec AGwww.heitec.de

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Intelligent networking of

machine tools and visualization

of process data guarantee

a consistently high level of

availability of the machines

and production capacities.

ongoing processes at any time. This forms the basis for optimal and highly efficient use of pro-duction. Additionally, direct access to the machine park, which often involved multiple manufacturers and machine generations, can help to optimize machine run times, tool use, changeover times, and ca-pacity planning of the respective operating personnel. Furthermore, connection and net-working guarantee a consistently high level of availability of the ma-chines and production capacities. To that end, a number of tools are available: for diagnostics, remote maintenance support, a mobile


industrie 4.0 area

EMPIRICAL INDIVIDUAL MACHINE DATA IN A DATA MODEL

Energy-sensitive planning of machining processesToday’s CAM systems offer many helpful features for digitalization such as trajectory generation and collision control. The time and energy required per workpiece, however, cannot be forecast with sufficient accuracy. The reason for this, amongst other things, is the lack of consideration of auxiliary process times and missing data va-lues for energy consumption of the machines to be used for the re-spective process states. Author: Dr. Volker Wittstock

In the research project, a machi-ning example (milling) was used to develop and implement a methodthat allows for machine-indepen-dent and therefore realistic fore-casting of time and energy require-ments. The basic idea is the alloca-tion of theoretical process parame-ters and experimental machine da-ta regarding time and energy tothe standard NC program codeoriginating directly from the CAM system.By linking an empirically deter-mined energetic model of the ma-chine tool with the forecast sys-tem, the existing data model of theproduction process is further enri-ched and individualized for each

machine used. This digital twin can be applied to all machines al-ready used in the industrial envi-ronment and is not limited to new machines. The measurement, which only needs to be conducted one time, also makes the user inde-pendent of costly sensor retro -fitting.The energetic model contains data that is won by measuring real ma-chines that exist in the workshop. This includes the energetic values such as base load or power con-sumption of the coolant supply on the one hand, and machine-speci-fic thresholds for speed, accelerati-on and jerk on the other hand.Furthermore, the times and energy

demands measured for tool andworkpiece exchange (standardfunctions) are stored. In order to develop a realistic timeforecast, jerk-limited motion profi-les are calculated for the respectivekinematics. The energetic forecastis based on the time determinedand the power demands of the pe-ripheral auxiliary systems (generalbase load, coolant lubrication sys-tem), the speed-dependent powerconsumption of the drives, and atheoretically determined processperformance based on known for-mulas of specific cutting force (kc)and metal removal rate (Q).The forecast software of the indus-try partner is deliberately keptCAN system neutral. Both the ope-ration as well the result illustrati-on can take place directly in aCAM or PM system. The ability tointegrate into an established CAD/CAM/NC workflow is necessaryin order to achieve a high level of acceptance and was thereforeshown using the example of Sie-mens NX and Teamcenter. Theproduction planner therefore getsan easy-to-use tool that supportshim in the development of time-,energy- and therefore cost-optimi-zed NC programs for milling. Thiscreates the prerequisite for effecti-ve and targeted energy and costmanagement. ■

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Institute for Machine Tools and Production Processes (IWP), Chemnitz University of Technologywww.tu-chemnitz.de/mb/ WerkzMasch

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industrie 4.0 area

TISIS – DIGITALIZATION OF THE AUTOMATIC LATHE

Ideally equipped for Industry 4.0 with TISIS So far, only few users and machine manufacturers have recognized the enormous potential of Industry 4.0 for production. One of the pioneers in this area is the Swiss lathe manufacturer Tornos, who already presented their TISIS software at the EMO 2013, a practical solution that has been continuously further developed since then.

Author: Dennis Keim

With TISIS, Tornos pursues two goals: immediate improvement of operating comfort, productivity and efficiency on the one hand, and the integration of individual machines into a communication network in real time on the other hand. With the TISIS software, the ma-chine can be set up virtually even when processing complex parts. The program provides support in the selection of suitable tools and prevents the mounting of incom-patible holders. That is why even unexperienced operators can carry out these tasks.As soon as the configuration is complete, programming is execu-ted in the usual way in ISO. The

system makes it possible to supple-ment the program with various in-formation such as plans, images, and text information. Changes can still be made after the program has been transferred to the machine via WLAN or a USB stick. Other main elements of the soft-ware that can be used to increase operating comfort and efficiency are parameter programming, the library function for ISO processes and the calculation of part proces-sing time. The part processing time is calcu-lated automatically during part programming. All these features show that TISIS was developed by practical users for practical users and is developed further continu-

ously with an ongoing dialogue. The operators always have all re-quired information and the correct settings. TISIS provides them with more interactive tools so that they are not just restricted to a simple keyboard. As an option, the opera-tor can see all machine data as well as data for production moni-toring in real time on a tablet or smart phone. This information is not only im-portant for the operators, but first and foremost for the production planners. At a later stage, they can also monitor their machine park or individual machines on their smart phone. The software shows alarms or error notifications with a complete alarm history so that detailed traceability is ensured. Together with Mastercam, TISIS offers a CAM solution that provi-des support in the execution of complex programming tasks, 3D simulation and 3D collision moni-toring. This constitutes a measura-ble advantage for Tornos clients, especially when it comes to the processing of complex parts. ■

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Tornos Technologies Deutschland GmbHwww.tornos.com/de

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industrie 4.0 area

INDUSTRY 4.0 IN BAVARIA – PRODUCTION AND BUSINESS MODELS OF TOMORROW

Developing new business modelsThe project „Industry 4.0 Bavaria – Production and Business Models of the Future“, organized by the VDMA Bavaria and supported by the Bavarian State Ministry for Economy and Media, Energy and Techno-logy, is geared towards supporting mid-sized companies in particu-lar on their way to becoming digitalized and networked companies. The goal is to identify possible actions and to highlight the concrete benefits associated with Industry 4.0 for small and mid-sized com-panies. Author: Thomas Kinkeldei

The topics of digitalization pene-trate many levels and do not only affect production and develop-ment, but all areas of a company. That is why our project addresses the many different approaches for faster, more efficient and better products, processes and services as well as new sources of revenue. To that end, we network mid-sized companies in Bavaria and create

bridges between both suppliers and users of digitalization topics. Examples for topics are amongst other things preventive mainten-ance, use of data within compa-nies, protection of IT security, and redesign of the working environ-ment. However, our project is pri-marily focused on the topic of new digital business models.

The digital transformation of the economy is in full swing. The change that is becoming apparent in areas such as commerce or hos-pitality now also enters the indus-try with force. A key element on the successful way towards digita-lization is the expansion of the in-cremental development of new technologies or processes to the development of new digital busi-ness models for the whole compa-ny. But how should these topics be approached? What can entrepre-neurs do to ensure that their own business model perseveres and that new market players do not take them by surprise? We offer special support in our events and work-shops to deal with these questions and use state-of-the-art research and methods to prepare Bavaria’s companies for this challenge. ■

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VDMA Bayernhttps://bayern.vdma.org

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wards suppor-

ting mid-sized

companies in

particular on

their way to be-

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zed and networ-

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Thomas

Kinkeldei,

VDMA Bayern


industrie 4.0 area

AN OPEN ECOSYSTEM OF PARTNERS, COMPETENCES, APPLICATIONS AND SOLUTIONS

Industry 4.0 Plug&Play – accelerate the digitalizationFrom cyber-physical systems to cyber-social systems and further: enabling the “augmented machine” to deploy an open, innovative and easy Industry 4.0.The presentation will describe as Alleantia’s Industrial Internet of Things open architecture can quickly and sim-ply enable the deployment of multifunctional Industry 4.0 solutions, by using both existing and new platforms, exploiting available tech-nologies and tools, from enterprise social network, to augmented reality and deep learning/AI applications. This is how Industry 4.0‘s opportunities increase exponentially. Author: Pier Luigi Zenevre

Alleantia, being an innovative In-dustrial IoT company based in Pi-sa, Italy, is rewriting the rules for Industry 4.0 transformations by offering a new middleware soluti-on, namely IoT Server, that bridges the gaps between machines, sen-sors and industrial devices and the broader IT applications. With plug-and play ease, Alleantia In-dustry 4.0 middleware can com-municate with virtually any ma-chine a company might be utili-zing in order to extract data for companies’ processes. Empowered by Alleantia technology, virtually any machine or device can instant-ly feed data into multiple enterpri-se IT applications, such as those from SAP, Microsoft and IBM. What’s more, enterprises that al-ready have specific, proprietary processes managed through ERP (Enterprise Resources Planning), logistics, asset management, and other IT applications, are quickly able to augment their existing pro-cesses by leveraging machine infor-mation. With Alleantia’s plug-and-play middleware, industry’s IoT capabilities can be greatly expan-ded as machines and devices beco-me smarter and fully connected to their enterprise IT systems and, ul-timately, to their decision-makers.Alleantia’s solutions utilize the property powerful XPANGO Li-brary – which includes about

4,500 drivers for devices, inclu-ding CNC and sensors from many bespoke vendors – and its freely available PLC integration tools to easily connect, with plug-and-play ease, machines to any IT infra-structure, IT application, and data analytics systems of a customer’s choice.In combination with IoT Edge Gateways from leading vendors which provide multiple analog, di-gital, serial, and Ethernet ports and offer adequate computing ca-pability, the Alleantia IoT Server leverages XPANGO library for ac-cessing information and inte-racting with sensors, devices and machines and integrates plug-ins for many on-premise and on-cloud IT infrastructures (SQL Server, Azure IoT, SAP HANA) with open REST API interfaces, allowing fast connection to any IT environment and enterprise applications such as Enterprise Resource Planning (ERP), Customer Relationship Management (CRM), Manufactu-ring Execution Systems (MES), Su-pervisory Control and Data Acquisition (SCADA), Product Li-fe Cycle Management (PLM) and Product Data Management (PDM). The Alleantia solutions support multiple concurrent con-nections to different applications and IT infrastructures, to provide engineered information to multi-

ple users in a secure and controlled way.Alleantia’s open platform through its IoT Plug&Play technology con-stantly supports its own ecosystem by allowing OEMs, developers and system integrators to imple-ment OT/IT integrated solutions.AI, deep learning and machine learning algorithms lend themsel-

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Alleantia Srlwww.alleantia.com

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Alleantia’s solu-

tions utilize the

property power-

ful XPANGO Li-

brary – which

includes about

4,500 drivers for

devices, inclu-

ding CNC, PLC

and sensors from

many bespoke

vendors to easily

connect, with

plug-and-play

ease, machines

to any IT infra-

structure, IT ap-

plication, and

data analytics

systems of a cus-

tomer’s choice.

ves to being integrated in Allean-tia’s open platform, because they enrich the user experience of in-dustrial assets (smart factories), support engineers responsible for products development in their de-cision making processes (smart products) and also enable new business models, for example by innovating maintenance or finan-cial services associated with capi-tal goods installed at shop floor le-vel (smart services). ■


industrie 4.0 area

ADVANTECH EMBEDDED-IOT

End-to-end Solution for the Digital TransformationAdvantech is a global leader of the industrial computing. The Com-pany Mission Statement is „Enabling an Intelligent Planet“: The fo-cus is to offer Solution Ready Platforms combining reliable Hard-ware and Software to easily deploy IoT & Industry 4.0 applications.

Advantech’s integrated IoT soluti-ons include sensor nodes, remote I/Os, gateways, Edge Intelligence Server (EIS), and the WISE-PaaS IoT software platform. Advantech Embedded IOT Gateways are la-test generation palm sized, Low-Power Gateways with Multiple Connectivity Options suitable for industrial environment.Based on latest generation Intel technology they can ensure effi-cient and high performance com-puting that – coupled with the WI-SE-PaaS IoT software – create the perfect add-on appliance to start the digital transformation of ma-chines and equipment. Advantech UTX-3115 and the new generation UTX-3117, are the perfect IoT gateways to fulfill all requirements of the digital transformation applied of the Ma-nufacturing Industry.The rich choice of certified RF connectivity expansions (WiFi, 3G, LTE, Sub 1 GHz) guarantees that the machines are always con-nected in whatever field applicati-on they are deployed.Fanless operation with wide range ambient temperature (-20~60° C) make the UTX family of gateways the preferred choice for industrial environment, while 12-24VDC power input and the different opti-ons for mechanical assembly (VE-SA, wallmount and DIN rail) al-low maximum versatility.Within our vision of a strong com-petitive positioning in the global IoT applications market – especi-ally for the manufacturing vertical – a central role is played by our

WISE-PaaS IoT platform of which the Remote Monitoring and Ma-nagement suite “WISE-PaaS/RMM” is part. WISE-PaaS/RMM focuses on re-mote device management and mo-nitoring; it represents – especially for machine tools builders – the ideal solution for the remote mo-nitoring of on-field assets and for enabling support services with ma-ximal effectiveness thanks to its reliable and secure cloud-based connectivity.In more detail, WISE-PaaS/RMM serves as an IoT Device Manage-ment platform to manage con-nected devices remotely, providing centralized management features, including HW/SW status monito-ring, remote control, system ba-ckup/recovery, etc. WISE-PaaS/RMM utilizes standard IoT proto-col, like MQTT, to communicate with IPCs, IoT gateways and sen-sors.The Device Management feature allows in-depth monitoring of the connected devices with HW moni-

toring functions (Power On/Off, KVM) and user access manage-ment (grouping, access levels, mapping, …)Within the WISE-PaaS/RMM suite a Business Logic editor – based on IBM Node-RED – allows for an intuitive flow design and graphical programming with drag and drop plugins integrated with RMM spe-cific functions. For the visualizati-on layer a web-based Dashboard Builder allows the quick realizati-on of custom dashboards suppor-ting simple widgets for data char-ting like Gauges, Sparklines, Pro-gress Bar, etc.The WISE-PaaS platform also of-fers a complete RESTful API pa-ckage to approach the implementa-tion of a custom application in a uniform, scalable and reliable envi-ronment with the support of a rich-ly documented SDK and Wiki. ■

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Advantech Europe BVwww.advantech.eu

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industrie 4.0 area

PORTA SOLUTIONS WITH MICROSOFT FOR THE FLEXIBLE PRODUCTION 4.0

Porta Open 4.0From the world crisis of 2008 a new method of production was born denominated „Flexible Production“. This method overturns the pro-duction principle of the machine tools, with the support of the soft-ware house and of the Cloud Microsoft.

At EMO 2017 the futuristic plat-form „Porta Open 4.0“ will be in-troduced, outcome also of the co-operation with the American giant Microsoft.The method „Flexible Producti-on“ combined to platform „Porta Open 4.0“ will be able to overturn some historical principles of the sector processes. „When a lot of production compa-nies have had to face drastic de-creases of orders, we have begun to think about developing a new project“ – remembers Maurizio Porta, CEO & Sales Managing Di-rector of Porta Solutions – „The old model of business based on the most fast possible cycles to produ-ce great quantities had collapsed. Now it is necessary to produce the sold quantities only, without stock and with consequent more liquidi-ties on the bank account of our customer.“ „The result of this thought is Mul-ticenter 4.0, a revolution for the sector, provided that a new pro-ductive model is adopted, with particular attention to the digitiza-tion and the integration“ – clari-fies Maurizio Porta – „For this we have developed „Porta Open 4.0“, a new technology.“„The platform „Porta Open 4.0“is based on the model Industrie 4.0: to be able to develop this plat-form we opened up to the world of the Cloud that than appears as not natural in a mechanical sector in which we have operated since 1958. Aware of the enormous opportuni-ties offered by these new digital technologies, we have chosen to work with Microsoft and with the team of Roberto Filipelli, Cloud &

Enterprise Partner Development Director, so that to adopt the best Cloud technologies with the most elevated safety standards, to sup-port the algorithms destined to en-ter the platform „Porta Open 4.0.“ ■

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Porta Solutions Spawww.porta-solutions.com

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industrie 4.0 area

ONLINE MONITORING AND CONTROL SYSTEM FOR TOOL DEFLECTION IN MILLING OPERATIONS

Feeling Machine ToolsAs a result of a constantly increasing demand for individual pro-ducts, the manufacturing industry has to face new challenges such as high numbers of product variants or small lot sizes. This develop-ment requires a high degree of flexibility regarding process monito-ring and process control to counteract varying boundary conditions and thus to reduce manufacturing inaccuracies and process time.

Autor: Haythem Boujnah

In milling operations, tool deflecti-on has significantly negative ef-fects on the quality of workpiece geometry and shape. Generally, this effect occurs in any machining process. Tool elasticity and process forces acting on the tool lead to deviations between the actual and a previously defined tool path. Costly re-machining may be necessary in these cases. In order to reduce tool deflection and to achieve the required tolerances, appropriate cutting parameters have to be determined. To provide these parameters, time consuming and costly experiments have to be carried out before each process se-tup. Especially for small lot sizes such as in die and mold producti-on, this procedure has limited ap-plicability in terms of profitability. The Institute of Production Engi-neering and Machine Tools (IFW) of the Leibniz Universität Hanno-ver has developed an online moni-toring and control system for tool

deflection in milling operations using a so-called “feeling” machi-ne tool (Figure 1).The main objective of the deflecti-on control is to maintain the actu-al tool deflection while being able to keep the tool center point on the preset tool path despite of dis-turbances within the machining process. Such disturbances are for example inconstant wall thicknes-ses of casted parts which in turn lead to varying cutting widths and thus to fluctuations of cutting for-ces and tool deflection.Equipped with several micro strain gauges, the spindle slide is able to detect the actual process forces and to provide high quality sig-nals. In addition force signals, in-formation about the bending stiff-ness of the applied tool is also re-quired to calculate tool deflection.

This parameter is determined by a machine-integrated cycle for stiff-ness measurement based on con-trolled soft collision between tool and workpiece. The tool deflection is measured and processed online during the machining operation. Finally, the actual tool path is de-termined and returned as an offset into the machine control. Compared to a reference process, this approach shows considerable improvement up to 80% regarding shape and size accuracies of ma-chined workpieces without exten-ding machining time (Figure 2). ■

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Institute of Production Enginee-ring and Machine Tools (IFW), Leibniz University Hannoverwww.ifw.uni-hannover.de

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Figure 1:

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industrie 4.0 area

FROM „JUST“ MACHINE MANUFACTURER TO FULL-RANGE SUPPLIER

The correct evaluationSchiess can look back on a tradition spanning deca-des. There are many machines at the market that car-ry out their tasks for a long time and to the satisfacti-on of their users. Especially for machines with a long product life, „Industry 4.0“ offers many advantages at product level.

Industry 4.0 is adopted amongst specialists for large machining cen-ters, especially in the area of data acquisition through remote main-tenance. The documentation of machine data and remote mainten-ance have been integrated into all machines for years and are activat-ed if requested by the client. Thissystem makes it possible to provi-de support immediately in case of machine errors (and therefore er-rors in the production process) and fix the error.There is the possibility to obtain information about the utilization of the machine or problems with the machine in real time – regard-less of where the client may be at the time. It is possible to identify irregularities in the collected data immediately and make adjust-ments to the process before the produced parts become scrap. For example, increased or unusual

electricity consumption may indi-cate a damaged bearing. If this da-mage is recognized in time, scrapcan be reduced or avoided. Thesystem also makes it possible toconduct preventive maintenance,i.e., the clients can avoid unplan-ned down times.

Security 4.0?!

Many people have reservationsabout remote machine access. Thesolution: Each machine connectedto the system communicates onlywith the web server. This not onlyallows for comfortable, centrali-zed communication, but also gua-rantees the highest level of securitythrough clear connections.

Outlook

There is a trend towards complete automation of this process, inclu-ding house-internal processes de-pendencies. This moves the machi-ne manufacturer closer towards being a full-range provider across the whole (now longer) lifecycle of the machine. A major challenge lies in the evaluation of the data volumes that are created, and most of all in evaluating the right data. ■

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Schiess GmbHwww.schiessgmbh.de

Machine status in real time.

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Production ma-chine VertiMas-ter VMG 6-PS.

Machine status in real time – main menu.

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industrie 4.0 area

RADIO-BASED COMMUNICATION IN PRODUCTION TECHNOLOGY

Potentials and challengesDue to increasing digitalization in the industrial sector, industrial automation is undergoing changes and is supported in the area of information and communication technology by initiatives such as In-dustry 4.0. The goal is information technology based networking of the industrial production. Author: Christoph Pallasch

Driven by this change, new para-digms and technologies are develo-ped in the area of industrial com-munication (for example dissoluti-on of the classical automation py-ramid) in order to create require-ments considering spatial or tem-poral flexibility and scalability through machine-to-machine (M2M) communication in combi-nation with additional sematic in-formation enrichment. Due to spatial flexibility, radio-ba-sed communication provides the opportunity to network system technology vertically without prior planning effort. Furthermo-re, it offers scalability by making it possible to integrate new commu-nication participants or call off in-formation of new participants and evaluate it in the system context. Radio-based communication can begin at various levels of use, from simple information transfer to cy-clical information exchange.

One required aspect within thecontext of I4.0 is the digitalizationand administration of physical ob-jects that are necessary for theoperative execution of productionor automation processes. In thecontext of the reference architectu-re model 4.0, they are described asassets that can be integrated intoan overall system with the help of an administration shell. Assets af-fect all physical objects (such astools, tool holders, parts, etc.),whereas the administration shell is a digital image of the object outfit-ted with additional methods in away that allows a higher level sys-tem (e.g., an MES) to access itstechnical production data and alsoexecute actions.Assuming that there is an adminis-tration shell for each asset, asset-to-asset and therefore M2M com-munication are possible as well,where the asset can autonomouslyforward production-specific infor-

mation via a communication inter-face, for example sending chan-geover data or processing informa-tion to cell or machine controls to exclude potential sources of error ahead of time and support the em-ployee in completing the order. Against this background, radio-based communication technolo-gies allow for flexibility that sup-ports the implementation of an ad-ministration shell for an asset.Another aspect is the cyclical in-formation transfer to real-time ca-pable communication systems, which is located at field level in the classical automation pyramid. The associated strict requirements re-garding latency and reliability po-se challenges for existing commu-nication systems that must be con-sidered for future solutions. Finally, 5G as the next generation of radio technology provides po-tential levers for vertical and hori-zontal networking that should co-ver industrial requirements of the future. In this context, introducti-on methods and utilization in form of licensing models must be taken into consideration. ■

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Machine tool lab WZL of the RWTH Aachenwww.wzl.rwth-aachen.de

Digitalization of assets.

Image: Laboratory for Machine Tools and Production Engineering (WZL) of the RWTH Aachen

Das


industrie 4.0 area

INTEGRATED PLANNING OF CYBER-PHYSICAL PRODUCTION SYSTEMS

Model-based production system planningA „model-based design methodology for cyber-physical products and production systems“ was developed within the framework of the joint research project mecPro². This methodology analyzes their in-tegrated development under the aspect of the special features of In-dustry 4.0. Author: Chantal Sinnwell

The approach of Model-Based Systems Engineering (MBSE) was used as base method to create spe-cific process approaches for the development of cyber-physical products and the planning of cy-ber-physical production systems that speak the same modeling language: SysML (Systems Mode-ling Language). Using this ap-proach, models can be managed within a joint system model and the interrelations between system elements of product and producti-on system during the product de-velopment process become appa-rent through the process of mode-ling. The presentation will explain the newly developed MBSE ap-proach for the planning of cyber-physical production systems in de-tail.

Paradigm shift

In principle, the approach for planning of a cyber-physical pro-duction system is focused on the integration of planning contents from different disciplines in the early development phases. Fur-thermore, it aims for a model-ba-sed rather than a document-centric collaboration between the discipli-nes involved. That constitutes a paradigm shift for the production system planning discipline, since MBSE is not very common there yet and it is different from the established approaches. However,MBSE reduces media breaks and facilitates the exchange of infor-mation between the disciplines.

The model-based planning process for cyber-physical production sys-tems is part of a more comprehen-sive process framework. There is adevelopment sub-process for boththe product and the productionsystem respectively. Both consist of the conceptual system draft andthe discipline-specific draft, whe-reas a SysML description system has been defined for the individualsystem elements for the systemdraft.The draft of the cyber-physicalproduction system consists of fourlevels. The context level defines thegeneral conditions and require-ments of the cyber-physical pro-duction system, such as the pro-duction program or basic pro-duction processes.The process level is the first step todetail the production processesthat are specified and structuredtechnically by production proces-ses. The structure and control levelis used to draft structure and con-

trol variants of the production sys-tem as well as their simulative re-view and optimization. The technical solution level breaksthe system down into additionalsub-systems that require anotheriteration of the approach, need tobe specified further in a productdevelopment process, or will bedetailed in the discipline-specificdraft. ■

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Institute for Manufacturing Technology and Production Systems (FBK), University of Kaiserslauternwww.fbk-kl.de

Characteristics of cyber-physical production systems.

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industrie 4.0 area

FIELD: THE OPEN INDUSTRY 4.0 ARCHITECTURE

Decision-making with Artificial Intelligence At the EMO, Fanuc shows how open the Industry 4.0 concept is. After all, not just own machines and controls are networked, but also pro-ducts of other companies. Decisions about certain control variables can easily be left to modules with artificial intelligence.

Author: Bernhard Lusch

About 70 partner companies, ma-chine manufacturers, sensor ma-nufacturers and exhibitors with external products will be integra-ted into the Industry 4.0 network. With this most comprehensive net-working so far, we present the AI network for Industrial IoT, “Field”. Other than competitor tools, the data for the Fanuc solutions does not necessarily go to a public cloud. Field offers mostly an “on-premise” solution: „Fog“ is an in-ternal cloud that remains within the company network, so to speak. In addition to additional data pro-tection, this has the advantage that the immense data volume is kept as close to the system as possible, where it can also be analyzed. Wit-

hout broadband exchange with a cloud server, Fog is also faster and more likely to provide close to real-time control. Already today, expert CNC sys-tems provide good data access compared to other systems via Fo-cas. Together with Field, the possi-bility is created to manage and analyze large amounts of data.

AI as a prerequisite

From the provider’s point of view, Artificial Intelligence (AI) is not just a part, but a major prerequisi-te of an Industrial IoT. „Deep Learning“ functionalities, for example, help robots with bin pi-cking to exchange the gripping strategies they have ‘learned’ over

time amongst themselves and to complete the bin picking tasks fas-ter than each individual robot could have done by himself – ba-sed on algorithms and not on pre-set gripping positions. What used to be a preset control loop in a CNC so far could be sup-ported by AI in the future and could thus be optimized, if not eli-minated altogether. Today, the ma-chine operator still decides which focus to set for his processing task. For example, he can choose bet-ween the tools “Power Optimizati-on” and “Motion Optimization” in the CNC. In the first case, the focus is on optimal energy use, while Motion Optimization opti-mizes motion models with the goal of improving cycle time. With the help of AI, this choice or a combi-nation of both modes could be op-timized. In the future, vibrations occurring during processing could be eliminated or reduced by artifi-cial intelligence. CNC and Field should have enough intelligence to make a decision about the control variable on their own. As a rule, the data and parameters required for the decision already exist today or can be collected easily. ■

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Fanuc Deutschland GmbHwww.fanuc.eu

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industrie 4.0 area

TURNKEY MULTI-SPINDLE TRANSFER MACHINES WITH RELEVANT TOOLING AND AUTOMATION

4.0 Horizontal and Vertical integration Buffoli Transfer designs and installs turnkey multi-spindle transfer machines with relevant tooling and automation in a logic of 4.0 Hori-zontal and Vertical integration.

Horizontal Integration: Buffoli develops fully integrated automated processes of metallic parts. Buffoli machines (either ro-tary or linear, from castings/for-gings or directly from bar stock) are fully integrated with advanced automation (with 3D vision sys-tems) and items of equipment for washing, inspecting, measuring, assembling, testing, palletizing… and additional peripherals (barco-de readers, RFID/NFC readers, tablets, smartphones, smartwat-ches, smartglasses, surveillance ca-meras…).

Vertical Integration: Buffoli vertical integration inclu-des:

∙ smart sensors and fully digital CNC

∙ data exchange with ERP or in the cloud

∙ real time reports and alerts on mobile devices

∙ entire process monitoring

∙ overall equipment management

∙ advanced diagnostic and equip-ment healthcare

∙ early warning and predictive maintenance

∙ employee productivity enhance-ment

∙ energy management

Buffoli turnkey lines offer:

∙ powerful integration

∙ maximum efficiency

∙ high precision and quality

∙ entire process control

∙ short change over times

∙ high flexibility

∙ multi-level communication; from shop floor to the upper level, between the machines, between the applications.

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1. 28.

27.

26.25.

29.

14.

15.

16.

18.

17.

20.

19.

22.

21.

24.

23.

5.

7.

9.

11.

12.

13.

10.

8.

6.

4.

3.2.Forum

1. Technische Universität München2. Technische Universität Kaiserslautern 3. Karlsruher Institut für Technologie (KIT) /

wbk Institut für Produktionstechnik4. Technische Universität Chemnitz5. Leibniz Universität Hannover Institut für

Fertigungstechnik + Werkzeugmaschinen6. Technische Universität Berlin7. Institut für Fertigungstechnik und Qualitäts-

sicherung (IFQ) / Institut für spanende Fertigung (IFS)8. Werkzeugmaschinenlabor WZL / RWTH Aachen9. FAGOR Automation GmbH10. Fraunhofer-Institut für Produktionstechnik

und Automatisierung IPA11. DR. JOHANNES HEIDENHAIN GmbH12. Maschinenfabrik Reinhausen GmbH13. SOFLEX Fertigungssteuerungs-GmbH14. Buff oli Automazione Industriale –

Electro Engineering15. ProduktionNRW VDMA Baden-Württemberg VDMA Bayern VDMA Forum 4.0

16. HEITEC AG17. INDEX-Werke GmbH & Co. KG18. Fanuc Deutschland GmbH19. COSCOM Computer GmbH20. Schiess GmbH21. WIBU-SYSTEMS AG22. Tornos Management Holding SA23. AXOOM GmbH24. MAPAL Dr. Kress KG / c-Com GmbH25. Gühring KG26. Plethora IIoT27. Fastems Systems GmbH28. Advantech Europe BV Alleantia Srl Leonardo PORTA Solutions Spa29. IndustryArena GmbH

industrie 4.0 area 2017 · IIoT, and Industrie 4.0“ Rüdiger Kügler,Wibu-Systems AG Lunch break...

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Transcript of industrie 4.0 area 2017 · IIoT, and Industrie 4.0“ Rüdiger Kügler,Wibu-Systems AG Lunch break...