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05/13/2022|Bosch Rexroth in Bursa

4× Faster with Digital Engineering “Trust is Important, Knowledge is Better”

With digital engineering, DMG MORI offers a future-oriented development environment for the design and realization of flexible automated manufacturing systems. 

“The more demanding the task, the more complex the requisite machining system and the greater the efficiency factor of digitization.”

Markus Rehm, Managing Director, DMG MORI HEITEC GmbH

Unique highlights include the dynamic virtualization of machines, assemblies and automation equipment as well as the possibility of simulating all internal system processes and movement sequences.

Industrial digitization marks a paradigm shift from traditional multi-stage production to the extensive networking of industrial production with internet-driven information and communication technologies. This opens up immense opportunities for DMG MORI to digitally enhance and holistically accelerate its own change from a manufacturer of products to a provider of customer- oriented product-service systems.

This can be seen in particular in the engineering of flexible, automated manufacturing solutions, as Markus Rehm, the Managing Director of DMG MORI HEITEC, emphasises. He believes in the simple principle: “The more demanding the task, the more complex the requisite machining system and the greater the efficiency factor of digitization.” This applies both to his own in-house interdisciplinary project development as well as to the process of system realization in close consultation with users.

As an internal example, Markus Rehm mentions the interplay of different disciplines from mechanical engineering, automation, application and process engineering, and control and software development. Here in particular, the tools of digital engineering have created the conditions for bringing together transparently the knowledge of all those involved in a central “point of truth”. This reduces the need for coordination on the one hand while preventing misunderstandings on the other.

1. The workpieces are fed in and out via a rotary storage system
2. There is a station for deburring the workpieces
3. The cleaning station consists of two cells
4. Workpiece handling within the WH Flex manufacturing system

1. The workpieces are fed in and out via a rotary storage system

The workpieces are fed in and out via a rotary storage system that ensures the alignment of parts does not change during machining.

2. There is a station for deburring the workpieces

There is a station for deburring the workpieces after machining on the DMC milling machines.

3. The cleaning station consists of two cells

The cleaning station consists of two cells, one for each of the DMC 80 H duoBLOCK machines,which are assigned a program in the DMG MORI Cell-Controller.

4. Workpiece handling within the WH Flex manufacturing system

Workpiece handling within the WH Flex manufacturing system is carried out by a Kuka 6-axis robot with a load capacity of 150 kg.

Most especially, digital engineering provides us with the data-based option of using virtual prototyping for early testing and validation of the system architecture as well as machining technologies, processes and internal system sequences”, says Rehm, who not only values the quality and efficiency of the development process, but also the time advantage of “weeks or even months”, depending on the complexity of the system. The decisive factor: All the advantages of digital engineering can be applied in equal measure to the added value for customers. This applies in particular to the virtual design and specification of the system in close consultation with customers, as well as to the positive effects before and during installation and commissioning. All functions of the digitally finalized system can, for example, be used for training employees or for planning, programming and simulation of intended tasks, while the real counterpart is still undergoing development. All the customer has to do on site to start production is connect the power. With regard to operation of the system, DMG MORI has focused not only on performance but also on sustainability. Markus Rehm argues his point with a convincing chronology: “Firstly, it is undeniable that there is no more efficient machine than one that operates automatically around the clock. Secondly, it is obvious that manufacturing systems with digital transparency can be continuously improved for the duration of their utilization. And thirdly, we are working on creative concepts for both the upcycling of systems as well as environmentally sound disposal or recycling of the components at the end of the product life cycle.” All that remains is the following advice: “Look before you leap.”

BOSCH REXROTH FACTS

  • 2 x DMC 80 H duoBLOCK
  • 6-axis robot with a load capacity of 150 kg
  • Deburring, cleaning, etc.

Thanks to digital engineering, it was possible to configure, virtually test and optimize this flexible, automated production project in record time. All that had to be done on the actual day was connect the power and press the start button. The employees had already been trained virtually in advance and the programs written and simulated. Bosch Rexroth is one of the world's leading industrial companies in the field of drive and control technology: “DMG MORI has been one of our partners for flexible automated manufacturing solutions for more than 20 years. We have tackled countless challenges together during that time. The new digital engineering approach still calms the nerves at the start every new system. Trust may be important, but knowledge is even better.”


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