Increase Uptime: Fewer Unexpected Failures Mean More Time for Production
Resilient and transparent maintenance scheduling provides actionable data to maintain an agile and responsive shop. The post Increase Uptime: Fewer Unexpected Failures Mean More Time for Production appeared first on Fabricating & Metalworking.
When you leverage technologies and connectivity you benefit from high levels of data-driven predictive and preventative maintenance capabilities, which boosts your production capabilities and reduces downtime.
The Future of Intelligently Networked Manufacturing
The DMG MORI Manufacturing USA (Hoffman Estates, IL) brand CELOS celebrated its premiere more than 10 years ago as the name of the world’s first app-based machine control system in machine tool manufacturing. The next generation, CELOS X, is an integrated ecosystem for data-based added value. The ecosystem provides holistic support in customers’ digital transformations to maximize machine performance. There are two core areas: CELOS Xchange and CELOS Xperience.
With 300 functions and more than 30 apps, CELOS Xperience offers consistency across all DMG MORI control variants – which will also be usable for third-party providers in the future, making it possible for the first time to map entire manufacturing processes end-to-end in a standardized solution.
A key feature is the ability to quickly and easily perform material and process-dependent calculations on the machines, such as speed, feed rate and spindle load. With predefined dimensions for fits and threads, which are taken into account in accordance with standards, CELOS Xperience halves the time and effort required for technology calculations. Document-based operator guidance minimizes the risk of operator errors, increases the efficiency of work processes and thus improves overall efficiency.
CELOS Xchange serves as a central hub and interoperable data space that can be used to connect a wide variety of players and assets in the manufacturing network. Under CELOS Xchange, sensitive production data is protected and intellectual property rights are safeguarded at all times. The system’s ability to guarantee data integrity also facilitates the creation of a reliable and transparent manufacturing process and creates trust among all parties involved.
With its core elements CELOS Xperience and CELOS Xchange, the digital transformation with CELOS X marks the transition from rigid to flexible and dynamic value chains. The system also underlines the need to make manufacturing systems and entire process chains quickly adaptable to changing requirements and configurations.
Intelligent Link Module to Boost Industrial Automation Data Transparency
With the SIRIUS 3RC7 intelligent link module, Siemens (Chicago, IL) now offers a quick and easy way to gain complete data transparency down to the field level. The plug-and-play expansion module combines information technology (IT) and operational technology (OT) with minimal installation and commissioning effort. This means that the data available at the load feeders can be used efficiently. As part of the leading automation concept Totally Integrated Automation (TIA) from Siemens, the SIRIUS 3RC7 intelligent link modules are seamlessly integrated into the existing automation environment. SIRIUS 3RC7 is part of the SIRIUS modular system for industrial controls.
A variety of load feeder parameters can be collected and evaluated directly, including voltage, current, phase imbalance, number of overload trips, and much more. The integrated diagnostic functions help detect and correct faults more quickly. Among other things, the data can be used for Senseye Predictive Maintenance, Siemens’ solution for predictive maintenance. It uses artificial intelligence, for example, to examine current fluctuations for anomalies that indicate a defect. This significantly increases the planning reliability for maintenance, availability, and cost-effectiveness of the system.
Data-driven Manufacturing with Integrated Machine Tool Monitoring Systems
Marposs Corp. (Auburn Hills, MI) demonstrated its smart manufacturing solutions including the Artis Machine Monitoring Solutions systems at IMTS 2024 in Chicago. A FANUC Robodrill was equipped with a drill, tap and milling cutter featuring Artis sensors that collect and stream real-time data. This provides visibility into the current status of production equipment, tools and cutting processes. The information is collected via spindle and linear axis power monitoring, spindle bearing vibration signals, machine crash signals for mitigating machine damages, and energy monitoring data signals, including overall equipment efficiency (OEE) basic figures to optimize the manufacturing process. This information helps to minimize damage caused by collisions and crashes, and helps predict maintenance needs, reducing energy usage and production costs, as well as improving throughput.
The demonstration also featured Marposs’ new Energy Monitoring System that leads to energy cost reduction, CO2 footprint reduction and electrical Condition Based Monitoring (CBM). It is equipped with multi-sensors and sensor less technologies that provide:
- Simultaneous analysis of main spindle and load power.
- Vibration signature analysis.
- Machine crash protection.
- Electrical CBM for energy monitoring.
The system also provides OEE process and tool monitoring data for visibility into tool comparison, cause of inefficiencies, production count, tool cost/part, part report, traceability and more.
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