Digitalisation in machine tool manufacturing How the machine tool industry can utilise the full potential of data
Utilising the full potential of data ensures not only higher productivity but also paves the way for increased user-friendliness, efficiency and flexibility in machine tool manufacturing. Siemens even goes as far as to promise “Infinite opportunities from infinite data”.
Under the motto “Digitalization in Machine Tool Manufacturing — Infinite opportunities from infinite data”, Siemens will be demonstrating at EMO Milano and at the virtual Siemens Machine Tool Days 2021, which will be held at the same time, how the full potential of data can be used for higher productivity. This is because combining the real world with the digital world enables manufacturers and users of machine tools to act flexibly and sustainably, the company argues.
The challenges are huge: The Covid 19 pandemic has significantly accelerated the pace of change in markets and associated demands. Added to this are growing individualization and the urgent need for more sustainability. This can be mastered with the help of digitalisation and automation. Siemens brings together the huge volumes of data generated in this process in a continuous cycle between the real and digital worlds. This enables employees in industrial companies to make appropriate decisions based on data and respond more quickly to trends and changes.
Sinumerik One is core element for Highlight Case with two technologies
At EMO Milano and the Siemens Machine Tool Days, Siemens will demonstrate how to react quickly to trends with the CNC Sinumerik One, which was launched on the market as a digital native in 2019. The focus of the trade fair appearance and the virtual event is a production plant that shows two machines controlled with Sinumerik One, a 5-axis milling center and a robot-based additive manufacturing machine. With these two machines, for example, gears of large gearboxes can be repaired instead of replacing them. Such large gearboxes are used in areas such as wind energy, where they are subject to natural wear due to the enormous frictional forces and therefore have to be replaced at certain time intervals.
At EMO Milano and the Siemens Machine Tool Days, Siemens will demonstrate how the gears are initially milled flat in the milling center. A robot is then used to rebuild the teeth in an additive manufacturing process. The final precision grinding takes place at the end again on the 5-axis milling center. The repair instead of new production not only saves material resources, but also about 60 percent of energy, the company claims. Sinumerik One represents the core element of the digital solutions Siemens has in store for tool makers. With the digital twin via Create My Virtual Machine, both machines could be developed, tested and functionally approved in parallel long before the real machine was put into operation. According to Siemens, machine builders thus get to a better machine faster and machine users faster to the right workpiece.
With the Digital Enterprise portfolio, the technology company wants to support companies where the current challenges lie: With the help of digital twins, such as Sinumerik One, and the use of future technologies such as artificial intelligence or industrial edge computing, machine builders and users can collect, analyse, understand the data generated and thus use in a meaningful way. This allows them to react quickly and flexibly to challenges and adapt their products and manufacturing processes to new requirements and save resources.
Greater flexibility and innovative technology for machine operation
As part of the EMO Milano and Siemens Machine Tool Days 2021, Sinumerik One offers new functions and technology updates that further increase performance, flexibility, and modularity. Visitors to EMO Milano as well as to the virtual Siemens Machine Tool Days will have the opportunity to see the new Sinumerik One Machine Control Panels (MCP) in action. With the new Sinumerik One MCPs, Siemens is launching an intuitive machine operation that offers CNC users more comfort, efficiency, and flexibility. The new ergonomic metal design in Blackline plus design can be integrated into existing operating concepts and fits 19-inch to 24-inch panels. It can thus be configured individually for customer-specific requirements.
New functionalities also make operation easier. The so-called Powerride combines the override switch with the NC start button for easy and efficient setup. With the integrated LED scale in the Powerride, Actual values can now be visualised. With the Powerride, the feed is automatically reset after the end of the set, which makes operation effective and easy. In addition, the Powerride provides haptic feedback through short vibration as soon as a defined limit value is exceeded. This increases the perception of these values and supports the blind operation of the panel. The QWERTY keyboard is provided as standard for the MCPs for the 22-inch and 24-inch variants, so users of these variants no longer need an additional keyboard. An integrated RGB LED lighting in the QWERTY keyboard enables customisable colour concepts for easy work. The Sinumerik One MCP can be used in harsh industrial environments due to its robustness. Its front complies with protection class IP65.
Siemens Industrial Edge — Extensions for machine tools
With Industrial Edge, Siemens wants to offer a concept in which both machine builders and users can flexibly use the advantages of data processing using edge or cloud computing as required. The company is also expanding its portfolio in the field of edge computing for machine tools for the real-time analysis of data on site in production and its intelligent use. As part of the EMO Milano and the Siemens Machine Tool Days 2021, the scalability of the edge hardware will be possible with the new hardware variants IPC 127E and IPC 427E. Siemens will also launch further new applications for various applications.