Industry 4.0DMG MORI1
Industry 4.0Path of Digitalization
Industry 4.0DMG MORI2
Industry 4.0 the 4th Industrial revolution
End of 18th century Early 20th century Early 1970s Today
Com
plex
ity
1st industrial revolution: Introduction of the mechanical production with the help of steam power
2nd industrial revolution: Introduction of the mass production with the help of the conveyer belt and electrical energy
3nd industrial revolution: Automated production due to SPS and Robotics
4nd industrial revolution: Communication between factory machines for automatic process optimization
Industry 4.0What is industry 4.0
Industry 4.0DMG MORI3
Industry 4.0
Industry 4.0DMG MORI4
Industry 4.0Opportunities for engineering
Production Machine
Industry 4.0DMG MORI5
Industry 4.0@ our production plant
Industry 4.0DMG MORI6
Design Department
Sourcing
Sales
Logistics
Warehouse
Production planning
Industry 4.0Shopfloor monitor – connected
Industry 4.0DMG MORI7
Industry 4.0Shopfloor monitor – functions
Order Information› Bill of material (BOM)› Customer specific design details› Sales order› Missing parts› Technical documentsWorkflow› Electronical material call› Escalation management › Complaints management› Report of operationOperational acquisition› Working time› Down time› Additional timesStatus information› Order status› Order progress› Current operation
Industry 4.0DMG MORI8
Industry 4.0CELOS - the I/F to the digital factory
Industry 4.0DMG MORI9
Industry 4.0CELOS – Messenger APP
Industry 4.0DMG MORI10
Industry 4.0PROCESS CHAIN
2. manufacturing 3. machining 4. service
› Job Manager
› Performance Monitor
› Condition Analyzer
› Technology Cycles
› Surface Analyzer
› Industry 4.0 package
› Service Agent
› Developer
› Update
1. preparation
› DMG MORI Process chain
› DMG MORI Virtual Machine
Industry 4.0DMG MORI11
Industry 4.0PROCESS CHAIN
3. MACHINING
› Technology Cycles
› Surface Analyzer
› Industry 4.0 package
Selected examples
Ergonomics and time savings
Measurement cycles workpiece quality
Machining cycles technology integration
Monitoring cycles process reliability
Tool sort cycle 3D Quickset® Grinding 2.0 MPC 2.0 – Machine Protection Control®
Industry 4.0DMG MORI12
Industry 4.0PROCESS CHAIN
4. MAINTENANCE
› Service Agent
› Developer
› Update Condition AnalyzerSignal green
Installation With documentation or video guided
Maintenance of customer
Delivery of goods
Condition AnalyzerSignal yellow
Service Agent Purchase, maintenance or DMG
MORI direct
Order e.g. at DMG MORI Service
Industry 4.0DMG MORI13
Industry 4.0Condition Analyzer │Performance
DMC 80 FD Industry 4.0
APP Condition Analyzer Highlights
Platform for visualising, analysing and predicting machine statuses across all machines
› Data storage interfaceCentral storage (Cloud) of the status data
› Visually status diagnostics - Individual machine level (My Machine)- Factory level (All Machines)- Across all factories (All Factories)
› User dependent access rights Information and reports
Industry 4.0DMG MORI14
Industry 4.0Condition Analyzer │Contents
DisplayMachine condition
Trend ofmeasurements
Process Monitoring› Direct monitoring and
controlling at the plant
› Short-term reactions when recognizing overloads
› Customization of machining operations
Analyse / certificationNC-programs
Optimizing / Quality check› Analyse and improvement
of machining operations
› Process certification /quality check
› Improvement of production and machine indicators
Integrated service videos
Guided maintenance› Integrated maintenance
videos for an easy independent maintenance
› Fast and easymachine maintenance
› Cost cutting
Increaseavailability› Recognizing machine
problems early and avoiding it
› Optimized exploitation and maintenance
› Target Information to maintenance
Industry 4.0DMG MORI15
Industry 4.0Condition Analyzer │Contents
Display machinery condition
Increase availability
› Engine problems at an early stage detect
and avoid
› Optimized utilization and maintenance
› Targeted information on maintenance on
maintenance and repair
Industry 4.0DMG MORI16
Industry 4.0Condition Analyzer
DMC 80 FD Industry 4.0
APP Condition Analyzer Highlights
Increase of the overall equipment effectiveness (OEE)Through recording, analyze and execute of machine data with direct feedback to customers and services
› Improved machine availability
› Projectable maintenance intervals and service costs
› Guides maintenance by service videos › guided machine
Industry 4.0DMG MORI17
Industry 4.0Condition Analyzer │Sensors - milling
Coolant system
Spindle
Hydraulic
Ball screw drive
› Fluid level*› Temperature*› Pressure*› Filter contamination› Interval oil exchange*
* Already prepared
› Pretension› Temperature
Pneumatic
› Air pressure*› Air flow› Filter contamination
Control cabinet
› Fill level*› Temperature*› Filter pollution*
› Temperature*› Filter pollution*
› Temperature spindle bearing*› MPC: Machine protectioncontrol
Coolantaggregate
› Rest of the paper bandfilter*
› Pollution of the double switch filter*
› Coolant level*› Quality of coolant
Industry 4.0DMG MORI18
Industry 4.0Condition Analyzer │Sensors - turning
* already prepared
Control of linear axes
Energy control Hydrauliccontrol
› Pressure, level› Temperature
Coolant lubricant management
› Pressure, flow rate› Filter check› coolant quality
Clamping control
› Torque, speed› Temperature
› Digital clamping pressure› Clamping position sensor
› Easy Tool Monitoring 2.0› Force, Speed› Temperature
› Energy consumption› Air consumption
HSP / GSPPneumatic
› Air pressure*› Air flow
› Fluid level*› Temperature*› Filter pollution*
Coolant aggregate
Industry 4.0DMG MORI19
Industry 4.0Sensors: Spindle – MPC (i4.0)
Spindle - MPC Performance
Advantages
Representation in Condition Analyzer
› In Process vibration monitoring› Machine quick shutdown in case of a crash› Torque monitoring during drilling and threading
› Increased availability through:› Avoidance of drill breaks through
determination of tool wear› targeted maintenance due
to bearing condition diagnosis of spindle› Imbalance analysis for Tools
› Error analysis by visual display in Condition Analyzer (lights)
› Avoidance of machine interruption› Cost savings by reducing of damages in case
of a crash
Specific report to maintenance department
CondIt Io n AnAl y z e r
Sensor package milling i4.0
Function in Sensor package i4.0_ Process monitoring, certification,
optimize and analyze
_ Machine and tool protection
_ Spindle bearing diagnosis
MPC (Machine Protection Control)Preventive machine protectionby quick shutdown
SGS (Spindle Growth Sensor)Spindle displacement sensor for determin-ing and compensating the stem extensiondue to bearing kinematics and temperature
IKZ flow rate controlMeasuring the flow rate of the coolant sup-ply pump to ensure the required coolingcapacity and for certification of processesand components
Function in Sensor package i4.0Function in Sensor package i4.0_ Precision
_ Process optimize, analyzeand certification
_ Process monitoring, certificationand analyze
_ Machine and tool protection
Machine protection Accuracy Process safety
Industry 4.0
Customer benefits_ Energy an air consumption
(DIN5001, energy-audit)
_ Media control for preventivemaintenance (flow rate,level, lubrication condition)
Advanced sensor controlAdvanced sensor analysis
Temperature controlTemperature-analysis-system
MPCMachine Protection Control
Easy Tool Monitor 2.0Tool monitoring
Customer benefits_ relocation compensation
_ precision drilling;5 0 % toleranceutilization
_ Data-Logger fortemperature fingerprint
Customer benefits_ machine and
tool protection
_ diagnosis of thespindle bearing
_ Process monitoring
Customer benefits_ Tool breackage
and wear monitoring
_ process optimizationan analysis
State control Accuracy checkMachine protection Process monitoring
CondIt Io n AnAl y z e r
Sensor package Turning i4.0
Industry 4.0
_ Partner APPsIn 7 Schritten zur eigenen APP
_ Noch intuitiver
_ Neue Innovationen
10 new APPs – 50 new functions
Performance MonitorOEE /KPI Analysis at a glance
_ Partner APPs – In 7 steps to your own app_ More intuitive
dMg Mo r I Ce l o s
The platform of DMG MORI with new innovations
Industry 4.0
Industry 4.0DMG MORI23
Industry 4.0Expansion stages of networking
MyMachine allMachine allFactory
Machine server
PC
Factory A Factory B
Smart Data
CELOS AppCondition Analyzer
Company server
Company server