FOCUS ON DIGITALISATION
Automation has cut costs , improved quality and increased productivity for many manufacturers
An eye on automation
Automated assembly operations are a key to success . They enable stable manufacturing , high- precision manufacturing and greater responsiveness to market demands . The Fraunhofer Institute for Factory Operation and Automation ( IFF ’ s ) digital instrumentation and information networks are increasing the transparency of aircraft manufacturer Airbus ’ s manufacturing operations and optimising collaboration between humans and machines .
For humans to be able to work properly in the smart factory of the future , new humanmachine interfaces will be needed : smart devices . These mobile devices are equipped with various sensors and connected on a wireless basis .
To seamlessly integrate the worker in production information processes , the Fraunhofer Institute for Production Technology IPT is taking a user-centred point of view in the design of its “ oculavis ” software platform . “ Oculavis ” can be used together with apps for terminal devices such as Smart Glasses or tablets to optimally control the factory ’ s information flow to and from the worker . For example , at Robert Bosch Elektronika Kft . in Hungary , “ oculavis ” uses Smart Glasses to make it possible for even untrained employees to conduct complex installation processes in a very short period of time .
Collaborative robots ( or cobots ) interact directly with humans and give manufacturers a competitive edge in the market . Different validation methods must be applied to humanrobot collaboration ( HRC ). For example , it is imperative that measurements are taken to determine the safety risks involved in any possible collisions .
HRC solutions may , in future , be linked to the factory control system via OPC UA or Industry 4.0 RAMI standards . Potential areas of application lie not in large-series production , but in the manufacture of medium and small batches . HRC makes sense in situations where employees can be relieved – ergonomically – of physically strenuous tasks , such as in maintenance work .
Automation has cut costs , improved quality and increased productivity for many manufacturers . It has also provided an answer to the challenge of finding skilled machine operators and personnel for the shop floor . Operations such as materials handling , sorting , storage and processing can be automated , which also ( if done properly ) exposes personnel to fewer levels of risk .
Effective CAD / CAM automation can also be used to counteract the shortage of skilled workers in production . The software enables users to create processes and process chains in the form of user-friendly sequences .
Digital twins
However , the digital transformation requires greater data analysis precision to proactively manage plants and machines . Of proven benefit in reducing these costs is the introduction of digital twins of machines . Siemens AG in Nuremberg even used digital twins in the development of a new control system .
The entire development of a machine , from its design , validation , engineering and testing through to a large proportion of its commissioning , can be carried out purely virtually . This elegant digital method allows development processes , including at the mechanical engineering and automation levels , to be conducted in parallel . Expensive prototypes will no longer be needed and risks can be reduced as the result of virtual , officebased commissioning . This helps the machine manufacturers to increase their operational efficiency and shorten the time to market .
End-to-end digital transformation also enhances the selling process by allowing concept discussions and sales talks with customers to be conducted around the virtual machine .
At present , the manufacturing and built environment sectors are developing their concepts of digital twins separately . A new initiative , the Apollo Protocol , is investigating the language barriers between digital twins of different sectors and developing recommendations to increase the interoperability between sectors .
Networked production
The smart factory describes a highly digitalised and connected environment where machinery and equipment can improve processes through automation and selfoptimisation . The benefits also extend beyond just the physical production of goods and into functions like planning , supply chain logistics and even product development .
Yet , the core value of the smart factory still happens within the four walls of the plant . The structure of a smart factory can include a combination of production , information and communication technologies , with the potential for integration across the entire manufacturing supply chain .
All these disparate parts of production can be connected via the IoT ( Internet of Things ) or other types of advanced integrated circuits , which enable sensing , measurement , control and communication of everything happening throughout the manufacturing process . n
AirBOX portable component monitoring on a material delivery unit or MDU . Image credit : © Fraunhofer IFF .
ISMR December 2021 / January 2022 | sheetmetalplus . com | 17