is exceeded, an active warning occurs and
the load can be adjusted immediately.
This also covers vibrations on the machine
components. Moreover, the effects of
temperature fluctuations on the forces can
be checked by using the operating panel.
Demand-based lubrication on the machine
also ensures that resources are saved,
while also safeguarding the bearings’
functionality and thus the performance of
the machine. The sensors in the machine
send signals that allow, among other
things, analysis of the condition of the
lubrication film at critical points in the
machine. If the condition is no longer
sufficient, a signal will be sent to the
Schaeffler CONCEPT8 and the required
quantity of fresh grease is delivered to
the bearing position. Machine downtimes
caused by insufficient lubrication can
therefore be eliminated. Furthermore,
the CONCEPT8 reports on the remaining
quantity of grease in the cartridge. Usually
the grease cartridge filling levels had to
be checked directly on the machine. Now
it can be controlled digitally on mobile
devices.
PRODUCTIVITY GAINS
The diameter and roundness must
comply with the target specifications to
approximately two microns. With this
project, Schaeffler wants to demonstrate
that Industry 4.0 is not an abstract, remote
vision but can make a contribution to
added-value today.
Sebastian Mergler, Project Manager,
Digital Services at Schaeffler comments:
“In more than 60 different positions, the
machine is equipped with sensors that
record measurement values for pressures,
vibrations and forces. These are primarily
integrated in components that Schaeffler
already supplies, such as in spindle
bearings and linear guidance systems.
These components are positioned precisely
where things move on the machine.”
“The machine tool’s condition is
effectively transparent at any time. Every
day, production processes become
more efficient and easier to plan. The
machine operator can schedule bearing
replacement, which avoids unplanned
machine downtimes,” he adds.
Valuable data is generated at these
measuring points, which is saved not
only in the machine itself but also in pre-
analysed form in the Schaeffler Cloud.
Communication with central servers takes
place via a secure gateway. The condition
of individual components on the machine
tool can be viewed at any time, either using
the operating terminal on the machine or
using a device connected to the Internet,
such as a tablet or smartphone.
In order to clearly categorise the measured
data, each component manufactured on
the new machine receives its own ID by
applying a unique Data Matrix Code. All
data generated during milling or in the
subsequent machining processes can
therefore be assigned later to a specific
component. By comparing the data for
the individual components, Schaeffler will
be able to quickly recognise deviations,
correct these, and in turn continuously
optimise the manufacturing processes.
The possibilities are huge, ranging from
even higher precision in soft machining,
to reducing energy consumption and
lubricant supply.
Ronny Hüttner, Precision Bearing
Technology at Schaeffler says: “Recording
the load data, particularly for the main
spindle, the linear guidance and the
TCP [tool centre point] allows potential
overloads to be made transparent.
This is beneficial to both the machine
manufacturer and the operator. The user
interface is the central interface here,
providing the user with precise data
about the current status of the production
process. Determining the forces allows us
to further optimise the load conditions in
the machine.”
IMPROVED MACHINE
OPERATION AND
MAINTENANCE
To set and inspect the precise machine
load is a very complex task. The operating
panel at the new machine tool allows the
correct main spindle operating load to be
set and the current loads can be monitored
whenever this is needed. If the load limit
The pilot project in Hoechstadt hopes
to demonstrate how significant the
productivity gains are through the
improved use of data. What is important
is that the project uses a real production
process, which means Schaeffler can
identify how Industry 4.0 works in practice,
where the challenges lie, and how added
value can be generated. Ultimately, it
is hoped that Schaeffler will benefit
from the pilot project in two ways. First,
the company can present itself to the
manufacturers of machine tools as a
solutions provider for Industry 4.0, while
also using the knowledge within its own
production processes.
Sebastian Mergler concludes:
“Digitalisation allows us to take the
next step towards Machine Tool 4.0,
allowing all process and quality data for
manufactured parts to be traced. In the
future, data analyses will even make it
possible to predict quality results. In other
words, machine operators can proactively
influence the manufacturing process.”
About Machine Tool 4.0
Machine Tool 4.0 is a collaborative
project between Schaeffler
and DMG Mori, which connects
existing technologies such as
sensors and digitised components
to the Cloud – a real step towards
true digitised production.
The collected data from the
machine tool is evaluated both
locally and in the Schaeffler Cloud
in order to feed the results back to
the various site locations.
www.schaeffler.com