Although not visible from the outside, the two DMC 80 FD duoBLOCK machines of the innovation project “machine tool 4.0” are nevertheless packed full with intelligent sensors as the basis of condition-oriented service and maintenance. To achieve this more than 60 sensors have been installed on elementary components of the FD machine.
Calculable availability of means of production ranks as a decisive factor in the realisation of cyber-physical production networks. This has led to the optimisation of service and maintenance processes progressively moving away from the back burner and into the limelight. That is why DMG MORI has collaborated with Schaeffler Technologie to start the innovation project “Machine Tool 4.0” taking the mill/turn centre DMC 80 FD duoBLOCK as a specific example. To achieve their aims more than 60 sensors have been installed on elementary components of the FD machine. Together with other (obligatory) status information all data are now captured in realtime and analysed using specially developed algorithms. As a result the evaluation of the data provides qualified insights into the probable occurrence of different process and production faults. This in turn enables users to take targeted measures in advance for the first time, where currently unplanned machine downtimes quickly render capacity planning a waste of time. The extent to which the above-mentioned theory is actually implemented in day-to-day machining routine can be experienced live by visitors to the DMG MORI stand at the EMO in Milan. Energy and running costs have also been reduced significantly in addition to the increase in availability and simultaneous reduction of service costs. This new “knowledge” also constitutes the basis for the sustainable optimisation of processes, products and machines.
Future-orientated joint project
“Industry 4.0“ is the hot topic of the moment. The fundamental ambition of the 4th industrial revolution is the individualised manufacture of products in digitalized, de-centralised, self-controlling cyber-physical production systems. On this basis every customer is to be offered his/her product customised to the conditions of mass production and have it delivered within the shortest possible time. So much to the vision. The status quo, of course, looks very different. Not even basic and more importantly globally coordinated rules and standards are in place yet.
But DMG MORI and Schaeffler Technologies were no longer willing to wait. With their innovation project “Machine Tool 4.0” they have together developed an intelligent machine – namely the DMC 80 FD duoBLOCK turn/mill centre. An example of this future-orientated “Machine Tool 4.0” will be on show at the DMG MORI stand in Milan. The second prototype will then already be up and running and in everyday use for series production in the Schaeffler Höchstadt plant and from there will enhance the EMO presentation with status data from the shopfloor.
Successful interplay of mechanics, electronics and information technology