smart factory together c2.pdf · monitoring regarding tool breakage and missing tools structure...

1Smart Factory Together

MARPOSS

Smart Factory

Solutions2

Smart Factory Together

스마트공장의핵심개념:네트워크의물리적시스템(Cyber Physical System)

Cyber Physical Systems 은새로운스마트공장의운영 node (operational nodes) 로나타냄.

제조모니터링및제어를위한 Smart Solutions 은 Cyber Physical Systems 을통하여스마트공장의설비로생산을반전시킬수있는시스템으로생각한다.


4단계의 Smart Factory

1. Integrate (통합) :생산공정을모니터링하고유연하게구성할수있는능력을증가하기위해생산라인의 Smart Solutions통합

2. Upgrade (업그레이드) : Smart Solutions으로기존측정장비를업그레이드하고필요한데이터에대한액세스가쉽고빠르게할수있는방법을구현

3. Adopt (채택) : 생산성과안전에타협없이기술능력, 신체적역량과문화적배경을허용하는인간 VS 기계인터페이스로접근방법을채택

4. Trust (신뢰) : 생산데이터는보안과신뢰보장되는로컬시스템또는클라우드에저장필요


Measurement and Technology in the Smart Factory

MonitoringSensors

HMICPS

Database

Interface

ProbesLasersBalancing

Adaptive Control

Statistics

Clouds

Optimisation

Organisation

Factory Net

MESERP OPC-UA

Network


Machine protection / Collision detection

Measuring of part geometry and position

Touching and contact between tool and workpiece

Regulation of cutting force / AC

Tool measuring

Monitoring regarding tool breakage and missing tools

Structure test

Data recording / documentation / statistics

Balancing

Machine condition monitoring

Milling, Drilling, Turning, Reaming, Broaching, Grinding, Gear-Hobbing, Pressing, Punching, Shaping, Cold-forming

Raw part machining Pre-machining Main operation Finishing Post process

Workpiece quality

Indicator gauges, plug gauges, laser used for workpiece and tool

Balancing / Dressing

GAP Control

Measuringgrindingprocesses

Non-desctructive testing

Optical

measuring devices

Leak detection, e.g. using Helium

Post process measuring

Final measuringmachines

Manual meas. device

GAP Control

Measuring in the process chain


Marposs Solutions

- MEASUREMENT AND CONTROL FOR MACHINE TOOLS

- DIMENSIONAL AND GEOMETRIC INSPECTION

- GAUGING FOR ASSEMBLY OPERATIONS

- STATISTICAL PROCESS AND QUALITY CONTROL

- FUNCTIONAL GAUGES, GO/NO GO, CALIPERS AND MASTERS

- NON DESTRUCTIVE (ND) TESTING

- LEAK TESTING

- INDUSTRIAL AUTOMATION

Work-piece

- Variations in allowances

- Material inhomogeneity

- Workpiece clamping

Machine

- Stiffness

- Accuracy

- Coolant and lubritorium

- Vibration/chattering

Surrounding

- Ambient

temperature

- Vibrations

- Electromagnetic

fields

Human

- Qualification

- Experience

- Response time

- Diligence

Organisation

- Production type

- Manufacturing

- Maintenance

Tool

- Tool wear

- Tool breakage

- Positioning

- Diversification of tool

properties

제조공정에영향을미치는주요요인


Smart Factory

Marposs Solutions for the Smart Factory

Field Bus Universal

Connectivity

Big- Data Analysis

Cyber PhysicalSystems

Augmented

Reality

Secure Local

Networking

Cloud I- IOT기술 (Technology)

Collaborative

Interaction

Increased Efficiency

Productivity

Data Security

Inform Decision Making

Flexibility &

Agility

Service Orientation

Management of Events

완벽한네트워크작업환경

목표 (Objective)

전략(Strategy)

Machine Tool

Applications3Smart Factory Together

Part Measurement

Tool Control

Machine and ProcessMonitoring

In-process gauges and touch probes; post-process gauges and plugs for interoperationalor final inspection

Contact and non-contact (laser) systemsfor tool measurement monitoring and compensation

Grinding wheel balancers; sensors to control force, power, vibration, noise, displacement; part, die and tool deformation

Marposs Smart SolutionsApplications for machine tools(grinding, cutting, forming and stamping machines)


Widest Range of In-process Applications on Grinders

WHEEL BALANCER (“in cycle”)

GAP ELIMINATOR

AUTOMATIC SIZE

CONTROL


Guaranteed finished part size tolerances

Optimized maching times

Automatic grinding wheel wear correction

Automatic cycle management without operator supervision or action

Lasting productivity

In process Measure


Acoustic Emission Sensors

Non-contact signal transmission from Marposs/Dittel’s rotating sensors.

Marposs/Dittel’s AE sensors can register even the slightest signal deviation under the hardest of

production conditions.

Marposs/Dittel’s AE sensors reduce air grinding.

The outstanding signal-to-noise ratio of Marposs/Dittel’s AE sensors ensures that your processes are

as stable as possible.

The AE signal are analyzed, evaluated and visualized very quickly by electronics to give you precise

reports on workpiece quality, tool wear and current machining conditions.

With Marposs/Dittel’s AE sensors installed, your grinding processes are in safe hands.


Wheel Balancing

-Assembly at the end of the grinding spindle-Maintenance-free

-Higly flexible balancing capacity and compact design-Suitable for high speeds of up to 20.000 rpm-Non-contact signal and energy transmission-Also available with integrated acoustic emission sensor

-Universally applicable to any grinding machine-Ideal for retrofitting into older machines-Speeds of up to 30.000 rpm-Customer-specific modifications for any machine-Compensates for unbalance by injection coolant into 3 -or 4

balancing chambers


Marposs Smart Solutions on Cutting Machines


NON-CONTACT LASER PROBE

FOR TOOL CHECKING (“in-cycle”

application)

TOUCH PROBES FOR

TOOL OR

WORKPIECE

CHECKING (“in-

cycle” application)

AIR / ELECTRONIC OR CONTACT /

ELECTRONIC

GAUGING EQUIPMENT

COMPONENT GAUGING AND FEED BACK

FOR TOOL COMPENSATION (“post-process”

application)COMPONENTS FOR TOOL &

PROCESS MONITORING

(“in-process application)

Part Monitoring

Automatic

measurement

e.g.: Part

identification throughautomatic inspection

Data exchange for

Production Monitoring

Focas, Remo Tool,OPC-UA

Several CNC protocol are

supportedFactory Wifi


Part Monitoring

Automatic

measurement

e.g.: Bore Gage on

cylinder block to

compensate tool wear

Data exchange for

Production Quality

Report

Factory Wifi

E9066 Industrial PC




supported

Automatic

measurement

e.g.: Tool wearand breakage

detection

Data exchange for

Predictive Maintenanceand Tool Life Monitoring

Factory Wifi


Tool Monitoring



supported

Process Monitoring

Reliably protect

expensive toolsSecure and

optimize

processes

Ensure quality

without

disturbing

the metal

cutting process

Detect faults resulting

in unscheduled

downtimes at an

early stage

Increase

productivity of

machine tools

Increase the

service life of tool

and machine

Preventive

maintenance

Energy saving


Sensors

Data acquisition through sensors

force and strain

coolant flow rate

All standard signals (0…±10V, 0…20 mA)

Strain gauges

digital spindle data

true power

acoustic emission

vibration


Tool monitor and control

Torque and force via

strain gage application

With/without inner coolant

Smart Tool Holder


Making Informed Decisions

Alarm and Event Messaging

• Alarm for User Defined Events

• Detection of Important Situations

• Early Warning for Performance Indicators



One Cable Control Network

The response from Marposs


Daisy Chain

Network

Topology

Monitoring Completely Networked Working Environment

Production

FactoryNetLevel

ERP-MESlevel


MMSB

OTG

FIELDBUS ( i.e. Profibus or Profinet

or Sercos )

ETH 10/100/1000 Mbit

USB

USB

ETH10/100 Mbit

ALARM LED

POWER SUPPLY AND FAST I/O

HDMIDISPLAY

MASTER CPU

A New Concept


A New Concept


WET AREA NODES

SW and Interface ( HMI and MI )


One-cable Smart Factory

Machine I

Process data

machine I

network

shop floor

Server with data base

(Event Logger)

Print a Mock report

Executionsystem

Office PC

Network office area

network

shop floor

Process data

machine II

Machine II

Network

shop floor

Machine n

Process data

machine n




blu.marposs.com

Manual

Gauges


Standard GaugingComponents

Display units, Industrial computers

SPC

Pencil type probes, gauging components for fixtures, interface units for data acquisition

Indicators, column and microcolumn displays, embedded gauge computers

SPC and quality control software

Gauging components

for end users, system integrators and gauge makers

Marposs Smart Solutions


Special

Applications


Inline gauging

Offline gauging

Non DestructiveTest (NDT)

Assembly and Test

Gauging machines and automatically loadedstations for 100% dimensional and geometricinspection

Manually loaded benches and hand-held gauges(variable and attribute types)

Systems to detect hardness inconsistencies and material flaws (cracks, pores,…)

Automatic solutions for assembly and leak test

Gauging and testing systems

Marposs Smart Solutions


This document and its content are confidential and exclusive property of Marposs S.p.A., Bentivoglio (BO), Italy. Without prior written consent, they cannot be used, totally or partially, for purposes different from those expressly allowed. Offenders will be prosecuted. The rights of third parties are acknowledged to the respective owners.

MARPOSS, and other names/signs of the Marposs Group shown therein are registered trademarks or trademarks of Marposs or other companies of the Group in the U.S.A. and other Countries.© COPYRIGHT 2016 Marposs S.p.A. - All rights reserved.

smart factory together c2.pdf · monitoring regarding tool breakage and missing tools structure...

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