Faster, safer, more precise: DMG MORI Digital Twin for simulation and collision avoidance
DMG MORI is setting new standards in the optimization of systems and processes with the DMG MORI Digital Twin for collision control, simulation, and employee training. In the course of Digital Transformation (DX) – one of the four main pillars of Machining Transformation (MX) alongside Process Integration, Automation and Green Transformation (GX) – the digital twin is taking on an increasingly central role. As a digital image of your DMG MORI machine tool, the digital twin contains the workspace with all components and functions, such as movements, control functions, NC, PLC, and their cycles. This allows you to fully check your processes for possible collisions and optimize process sequences even before production.
Get your production ready for the future:
- Simulate and optimize your machining processes before a single physical cut is made.
- Avoid collisions and reduce production downtime, costs, and collision risks.
- Accelerate the market launch of your products.
Highlights
The machine model for the DMG MORI Digital Twin is the digital replica of your DMG MORI machine. The model contains all elementary components of the real machine and has all relevant information on the machine kinematics. The machine model is used within the DMG MORI Digital Twin Software together with virtual images of the workpiece, the clamping devices and the machine control to simulate the NC code. This eliminates the time-consuming and resource-intensive ramp-up of production on the machine. Even new processes can be set up digitally while your machine is in operation.
- 100 % collision free trial out
- 40 % faster production ramp-up
- 75 % savings on testing
BENEFITS
100 % collision free trial out
With the integration of the geometric and kinematized machine model in the DMG MORI Digital Twin as well as the specific digital NC and PLC, the simulations are an exact replica of reality. This enables a collision avoidance in the working area between tool, workpiece, spindle, or clamping device before the process starts. This ensures that your processes run collision-free. The simulation covers the entire machining process as well as all non-productive tasks such as tool changes or transferring the workpiece to the counter spindle.
Advantages of simulation with the DMG MORI Digital Twin:
- Collision verification in the working area for safe processes
- Realistic simulation of the machining process
- Simulation of non-productive tasks, such as tool changes
40 % faster production ramp-up
Accelerate your production ramp-up with the DMG MORI Digital Twin Software through fast machining simulation in the virtual world. Train your employees and test processes digitally in advance, even before your machine has been delivered.
- Test and evaluate your programs before the machine is delivered
- Quick simulation of your machining process
- Digital employee training on virtual DMG MORI Machines
75 % savings on testing
With the DMG MORI Digital Twin you can program in the usual way. Use the shopfloor-oriented programming as on your real machine, parallel to production and benefit from the availability of our DMG MORI technology cycles in the Digital Twin software. Test and optimize processes and sequences virtually before transferring your simulated and validated programs to the real machine. Programming with the DMG MORI Digital Twin allows you to use your machine efficiently for production.
- Shopfloor-oriented programming parallel to production
- Use of Technology Cycles in the DMG MORI Digital Twin
- Virtual testing and optimization of processes
Technical Features
Exact digital replica of the customer-specific machine
The machine model is the exact geometric, digital representation of your DMG MORI machine, which does not require any assumptions or simplifications of the geometry or kinematics.
Complete PLC and NC simulation
The use of digital machine PLC and NC in the DMG MORI Digital Twin enables all processes on the machine, e.g. axis movements or switching operations on additional units, to be taken into account during the simulation. This allows precise time studies of your processes to be carried out.
Simulation without interpretation
The digital image of the machine PLC and NC performs a complete simulation of the machining process and not an emulation (approximation of real behavior).
Use Case 1: Operator Training
With increasing complexity of products and processes, the shortage of skilled workers in today's manufacturing industry is intensified. The DMG MORI Digital Twin offers you the opportunity to train employees on DMG MORI machines in a secure, digital environment, e.g. with our trainers from the DMG MORI Academy or in special offers for educational institutions. Get to know the functionalities and become a competent user of CNC technology - before your real machine is delivered.
This gives you the opportunity to test and verify programs for the new DMG MORI machine before delivery.
- Virtual machine training
- Training on the machine before the machine even arrives
- Reduced training costs
Use Case 2: Machine Programming
Increasing the spindle hours of your machine tool is an important lever for higher productivity. Interrupting the production process by programming your machine tool can lead to a reduction in spindle hours. With the DMG MORI Digital Twin, you can move the programming of your machine tool from the shopfloor to the office or from the machine tool to the virtual world. The DMG MORI Digital Twin allows you to create your NC program in the same way as on your real machine while your machine tool is manufacturing.
- Process-parallel programming
- Virtual use of all functions
- Optimization before machining
Use Case 3: Simulation and time studies
Collisions during production can lead to major maintenance as well as production downtime. These downtimes are not only a major cost driver, but also have a negative impact on your sustainability. The DMG MORI Digital Twin enables a collision check to virtually detect and avoid potential collisions even before production begins. This allows you to check your G-code for errors and precisely plan the production time, including all non-productive processes. This supports you in planning and calculating your production.
- Virtual crash detection
- Checking the G-code
- Carrying out time studies
Success Story
Airbus Helicopters GmbH
Pain point :
A major challenge in production at Airbus Helicopters is designing new components as efficiently and reliably as possible.
In central programming, the programs are created in the CAM programs available there. As only the NC code is interpreted within CAM systems, without the software knowing the exact machine environment or the control system, these simulations have limitations.
Solution :
Airbus Helicopters has found an optimal solution with the DMG MORI Digital Twin. The digital image of an individual DMG MORI machine tool contains the workspace with all components, including all functionalities such as movements and control functions as well as the NC and PLC and their cycles. With the Digital Twin, Airbus Helicopters ensures that machining on the machine is collision-free and achieves a significantly faster production ramp-up thanks to the virtual tests, while the systems continue to produce.
Customer name & position:
Steffen Rössner and Thomas Heinrich
both responsible for programming in mechanical production at Airbus Helicopters
Customer quote :
With the Digital Twin, we were able to significantly reduce the ramp-up time for new components and the possibility of crashing is almost impossible.
FAQ
FAQ
System requirements for DMG MORI Digital Twin:
- Operating system: Win10 / 64bit or higher
RAM: at least 32 GB - Processor: Intel Xeon CPU E3-1225 v6 @3,3 GHz
(Recommended: Intel Core i9-12900K, 3,2 GHz) - Hard disk space: at least 80 GB free disk space (recommended: 200 GB free disk space)
- Graphics card: NVIDIA Quadro P2000
(Recommended: 12 GB NVIDIA RTX A 2000) - Monitor: 2x min. 21" (min. resolution 1280 x 1024) - the installation instructions say 19".
The following additional requirements apply to the integrated CELOS:
- Hard disk space: additional 25 GB
- Monitor: at least one of the above monitors with FULL HD (1920 x 1080).
The DMG MORI Digital Twin Machine Model can only be used in the DMG MORI Digital Twin Software. The DMG MORI Digital Twin Software is therefore mandatory.
Yes, you can get a machine model before the real machine is delivered to you. However, the prior machine model is a generalized machine model. Eight weeks after delivery of the real machine we can supply you with the DMG MORI Digital Twin Machine Model of your specific machine. This machine model contains all geometrical and kinematical information in accordance with your real machine.
The DMG MORI Digital Twin is available for DMG MORI Machines with SIEMENS and HEIDENHAIN controls.