machine monitoring system...schuler’s answer to industry 4.0 is the smart press shop. in the...

SMART PRESS SHOPMachine Monitoring System

Schuler is the technological and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and for lightweight automobile construction. Its customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance, packaging, energy and electronics industries. Schuler is a leading supplier of minting presses and implements system solutions for a wide range of different high-tech sectors. The company has a presence in approximately 40 countries with roughly 6 600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

ABOUT THE SCHULER GROUP – WWW.SCHULERGROUP.COM

PROCESS SIMULATION

INTELLIGENT DATA SOLUTIONS

CONNECTED FORMING SYSTEMS

Schuler’s answer to Industry 4.0 is the Smart Press Shop. In the intelligent and fully networked press shop of the future, it will be possible to accurately predict potential downtime with the aid of sophisticated sensors and actuators, along with the data they collect, and to avert this downtime well in advance. This helps to ensure our customers’ productivity and increase the quality of the parts they produce, while also reducing energy requirements. As a result, the Smart Press Shop delivers improved reliability and increased cost-effectiveness for the field of forming technology.

The Machine Monitoring System. A product solution from the Smart Press Shop. At the heart of Schuler’s digital toolkit is the Machine Monitoring System, which features six different function areas. These areas can be used to collect, analyze, store, and evaluate production conditions. The system is compatible with both new and existing machinery, and can be operated and controlled by custom-ers directly on their plant equipment, via their servers, or over their network—and in the future also from the cloud.

SMART PRESS SHOP – FOR THE INTELLIGENTLY NETWORKED PRESS SHOP OF THE FUTURE

MACHINE MONITORING SYSTEM: DIGITAL TOOLBOX OF THE SMART PRESS SHOP.

Schuler's Smart Press Shop secures the competitive edge in forming technology.

PROCESS SIMULATION

INTELLIGENT DATA SOLUTIONS

CONNECTED FORMING SYSTEMS

The six function areas of the Machine Monitoring System.

SMARTDIAGNOSTICS

PROCESSMONITORING

TRACK &TRACE

CONDITIONMONITORING

POWERMONITORING

BDE / OEEMONITORING

»The digital transformation of the press shop is already in full swing. The Smart Press Shop allows not only large automobile manufacturers but also medium-sized suppliers to produce more efficiently and generate fewer rejects. In this way they gain the necessary competitive edge with us. Schuler is bringing metal forming technology into the digital future at top speed.«

MACHINE MONITORING SYSTEM

Domenico Iacovelli, Chief Executive Officer at Schuler AG

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SMART PRESS SHOP / MACHINE MONITORING SYSTEM

Machine availability is increasing thanks to rapid error analysis.

Works like the black box in an airplane: Specific data produced during production are automatically stored on a continuous basis. In the event of a malfunction or failure, a retrospective analysis can be performed to determine the cause, for example, a software error or defective component.

Best practice: Smart Press Shop. Smart Diagnostics will be used in the innovative press shop that Schuler is realizing together with its customers. In these Smart Press Shops, however, we go one step further: the continuous networking of production data with the help of machine learning will enable us to take intelligent production control and predic-tive maintenance to a whole new level.

Schuler is offering a press shop of the future that sets new standards in two respects – performance in industrial manufacturing and digital networking and readability of data streams throughout the entire production process.


RECORDING IN PROGRESS: SMART DIAGNOSTICS.

Data acquisition and data evaluation for all Schuler systems.

SMARTDIAGNOSTICS

www.schulergroup.com/smart_press_shop

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Condition monitoring makes it possible to avoid both unplanned downtimes and also the unnecessary replacement of parts.

Machine components are monitored for changes, wear and damage in order to optimize the maintenance process. For this purpose, regular test runs of the system are performed in which, among other things, vibration data, torque progressions and energy consumption are measured, stored and compared. Wear is also taken into account by considering the load (load spectrum) in the actual manufacturing process (“process monitoring”).

Best practice: servo press lines. Since 2016, Schuler servo press lines have been equipped with sensors in the slide and bed as standard. These sensors measure the acceleration per stroke. This means that our customers are already able to monitor the condition of the systems and the forming processes in detail.

Sensors can also be used to measure the vibration in the engine bearings, which in turn indicates possible wear at particularly critical points such as gearwheels and axles.

The demand for electricity, water and compressed air can, of course, also be individually identified, from the blank feed and individual presses to bed cushions and blank destacking.


OPTIMIZATION OF MAINTENANCE: CONDITION MONITORING.

Condition monitoring: monitoring of wear and changes in machine components.

CONDITIONMONITORING

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The aim is to increase process reliability and thus machine availability and to improve production and part quality. In addition, the setup time is shortened.

The raw data collected here is essentially the same as the data used for condition monitoring, but with one difference: Collection takes place during the actual production process instead of in a test run. Do the good parts correspond exactly to the ideas in terms of quality and quantity? Are the press force and vibration progression in order? Which parameters may need to be adjusted so that they are exactly in sync with the cycle?


FULL CONTROL: PROCESS MONITORING.

Process Monitoring: all system components at a glance.

Best practice: hot stamping. At Schuler’s Hot Stamping Tech Center in Göppingen, Germany, video and thermal imaging cameras provide a real-time overview of blank feeding, transfer and end of line, while the system continu-ously records process data in parallel. The information is collected by the numerous sensors in the press, die, furnace and cooling units. The system manages to merge and synchronize the enormous amounts of data.

The solution gives system operators a way to precisely check the production conditions of each to see whether blanks were heated to a high enough temperature, kept in the press for long enough, or were cooled in the proper amount of time. Not only does the software run on-site, it can also be used everywhere else as a Windows computer.

System master controller

FoL Robot

Qualityinspection

EoL

Marking

Press Feeder 1 Feeder 2

Tool change

TCP/IPProfinet

Other interfaces

Ethercat

Thermalinspection

Chiller Scrap container

Furnace

Data- base

Process

Condition

Power

Video IIOT device

Processdataacquisition

PROCESSMONITORING

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Power monitoring not only saves energy costs, it also helps to identify possible problems in the network quality at an early stage.

In this module, all relevant power supply and energy quality data for the system are stored and analyzed. What does consumption look like as a function of specific operating states? When does the optimal state occur? How efficient is the current consumption? When do voltage fluctuations or dips occur?

Best practice: Smart DC Grid. Our intelligent DC grid for press lines, the Schuler Smart DC Grid, is already in use in several press lines in the automotive industry. The background to this is that the individual presses in a line not only require electrical energy at each stroke, but also generate it during the cyclic braking processes. This energy can be transmitted via the intelligent DC grid directly to the presses, which are currently accelerating or forming and therefore need electricity.


BEST GRID AND POWER QUALITY: POWER MONITORING.

Energy-efficient Schuler systems can be operated even more economically with power monitoring.

POWERMONITORING

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The gapless documentation is incredibly valuable in the event of any quality problems.

The process parameters are documented online and assigned to the workpiece. Change trends can be tracked and indicate a necessary intervention if limit values are exceeded.

Best practice: railway. Schuler has also already demon-strated its ability to fully network different production facilities with its systems for constructing train wheels.


SEAMLESS PROOF OF QUALITY: TRACK & TRACE.

All relevant data per component are recorded at the marking station (example: wheel roller mill).

TRACK &TRACE

Quality documentation has the highest priority for these safety-related components. All relevant data can be recorded and archived for each part produced. The system links the information about the raw material used and its origin with the production conditions (e.g., “press force” or “part temperature”) and thus enables traceability.

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Continuous parameter logging enables real-time responses that are exactly in sync with machine cycles.

The production data acquired includes all planned and unplanned downtimes including their causes, fault messages, target/actual production and the quality of the parts. In this way, the system operators gain an overview of the production status and a basis for calculating the overall equipment efficiency (OEE).

The OEE is an extremely important system-related metric. It provides information about the changes from actual to target values in the areas of availability, performance and quality. The OEE is equal to 100 percent when the system produces nothing but acceptable parts at the full programmed stroke rate over the entire time of production. Any disruptions or errors will lower the number of accept-able parts produced – and by extension, the OEE – over the production period.

Best practice: hydroforming. At our Hydroforming TechCenter in Canton, Michigan (USA), we have already networked all our production facilities and recorded the machine statuses. The provision of the required data is the prerequisite for presenting the key performance indicators and thus for determining and increasing the overall equipment efficiency (OEE). The data is prepared by the system so that a quick glance is all it takes for the production manager to determine the total number of parts produced, how many of these parts are acceptable, and which shift had the best performance.


REACTION IN REAL TIME: BDE/OEE MONITORING.

The evaluation of the OEE enables a target/actual comparison of the system performance at any time.

BDE / OEEMONITORING

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FROM THE SENSOR TO THE SOLUTION: THIS IS HOW MMS WORKS IN DETAIL.


A press operator receives a fault error message on the new MSP 400 servo press: the process monitor integrated in the control unit detected an overload and stopped the machine within a few milliseconds. At a glance into the die, the operator recognizes that a sheet metal part has jammed and removes it again. The overload protection has prevented damage to the die and production can continue completely unimpeded.

But how did the press recognize the fault? With the help of the process monitor, which tracks the press force over the entire movement curve of the slide. If the press force exceeds a defined value at a specific operating point, the process monitor sounds an alarm and the press retracts the slide to relieve the die.

This is made possible by the numerous sensors that are integrated in the machine and record the necessary data in real time. The process monitor compares the press force with the slide movement and prepares the information for visualization. The data can also be stored in the company network or in a secure cloud for long-term evaluation.

MSP 400 servo press in monoblock design.

Comprehensive condition monitoring. The integration of additional sensors, e.g. for acceleration, oscillation or pressure, enables comprehensive condition monitoring of the system. The basis for this are frequency analyzes that provide information about possible wear in the gearing, bearing, or motor.

This prevents unplanned downtime and increases the productivity of the system. Furthermore, the process and condition data allow for complete quality control of the produced components.

CONDITIONMONITORING

Force

Convert

Data Bank

Envelope Curve View

Monitor

Hotline Teleservice

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SAFETY AND ADDED VALUE: SIX MODULES FOR MANY SCHULER SYSTEMS.

POWERMONITORING

CONDITIONMONITORING

TRACK &TRACE

SMARTDIAGNOSTICS

PROCESSMONITORING

BDE / OEEMONITORING

AUTOMOTIVE SOLUTIONS

Tryout press Yes Yes Yes Yes No No

Press line Yes Yes Yes Yes Planning in progress

Yes

Cutting line No Yes No Yes Planning in progress

No

Transfer press Yes Yes Yes Yes Planning in progress

Yes

HYDRAULIC SOLUTIONS

Tryout press Yes Yes Yes Yes No No

Press line Yes Yes Yes Yes Planning in progress

Yes

Transfer press Yes Yes Yes Yes Planning in progress

Yes

Hot Stamping Yes Yes Yes Yes Yes Yes

Hydroforming Yes Yes Planning in progress

Planning in progress


Yes

Composite Yes Yes Planning in progress



Yes

Forging Yes Yes Yes Yes Yes Yes

INDUSTRY SOLUTIONS

Tie Rod Yes Yes Yes Yes Planning in progress

Yes

Monobloc Yes Yes Yes Yes Planning in progress

Yes

Compact Presses No Yes No No No No

Forging Yes Yes Yes Yes Planning in progress

Yes

Blanking Line No Yes No Yes Planning in progress

No

Laser Blanking Line Planning in progress


Yes Yes Planning in progress


Schuler rolls out the Machine Monitoring System successively on all Schuler systems. Many products are already equipped with several MMS modules, others will follow.

METRIS

A STRONG PARTNERSHIP FOR THE DIGITAL TRANSFORMATION OF THE PRESS SHOPS.

Metris presentation at Hannover-Messe 2018.

The Smart Press Shop is part of “Metris - Industrial IoT Solutions”.

Under the brand name “Metris”, the ANDRITZ Technology Group is bundling its innovative IIoT solutions, which have been tested in many reference plants worldwide and which Schuler also uses.

More than ten years ago, ANDRITZ developed OPP (Optimi-zation of Process Performance), a system for optimizing the operation of machines and systems in the pulp and paper industry, and continuously improved it based on customer experience.

ANDRITZ has also further developed OPP for use in other business areas and offers solutions for a wide variety of industries. The technologies used are adapted to the individual requirements and needs of each customer. ANDRITZ is one of the world's leading suppliers of systems, equipment, and services for hydropower plants, the pulp and paper industry, the metalworking and steel industries, and for municipal and industrial solid/liquid separation. With 26,000 employees and over 250 locations in more than 40 countries worldwide, ANDRITZ supports its customers as a reliable and expert partner.

Schuler Pressen GmbHSchuler-Platz 1 73033 GöppingenGermanyPhone + 49 7161 66-0Fax + 49 7161 66-233

[email protected]

102E

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18-W

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Schuler is the technological and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and for lightweight automobile construction. Its customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance, packaging, energy and electronics industries. Schuler is a leading supplier of minting presses and implements system solutions for a wide range of different high-tech sectors. The company has a presence in approximately 40 countries with roughly 6 600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

ABOUT THE SCHULER GROUP – WWW.SCHULERGROUP.COM

machine monitoring system...schuler’s answer to industry 4.0 is the smart press shop. in the...

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